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Unread 07-29-2013, 10:57 PM   #1
KCR
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Default Ds obc

Have a 2002 DS that does not charge. Plug charger in an comes on but amp meter stays at zero. Tried a second charger with same results. Guessing its the OBC? How do I test? Can I use a Yamaha charger by replacing the plug? Will anything in the OBC be harmed or need disconnecting when using another charger?
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Unread 07-29-2013, 11:03 PM   #2
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Default Re: Ds obc

I found this for you on another thread posted by Crash Test Dummy! He helps out a lot of technical questions and has a great diagram repertoire in his database. And by the way, if it doesn't work for ya then blame him, I'm just coping and pasting to help....

try resetting the OBC

Resetting the Club Car On board computer - reset the OBC

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

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 07-30-2013, 01:33 AM   #3
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Default Re: Ds obc

Quote:
Originally Posted by KCR View Post
Have a 2002 DS that does not charge. Plug charger in an comes on but amp meter stays at zero. Tried a second charger with same results. Guessing its the OBC? How do I test? Can I use a Yamaha charger by replacing the plug? Will anything in the OBC be harmed or need disconnecting when using another charger?
I don't think you can use a non-CC charger with the CC OBC. Certainly do a reset and see if that helps. Let us know what happens
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Unread 07-30-2013, 07:08 AM   #4
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Default Re: Ds obc

Note that sometimes your OBC could be so shot that even the bypass methods don't get charger to come on. There are 2 options to fix your cart...first is get a new OBC obviously or you could get a automatic timer that you wire to your charger that will make the charger monitor the charge and not the OBC. The timer method is much cheaper and can be removed from your charger if you ever plan on fixing the OBC or whatever. PM me and I can give you more details
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Unread 07-30-2013, 07:26 AM   #5
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Default Re: Ds obc

Quote:
Originally Posted by cmar143 View Post
Note that sometimes your OBC could be so shot that even the bypass methods don't get charger to come on. There are 2 options to fix your cart...first is get a new OBC obviously or you could get a automatic timer that you wire to your charger that will make the charger monitor the charge and not the OBC. The timer method is much cheaper and can be removed from your charger if you ever plan on fixing the OBC or whatever. PM me and I can give you more details

. . . so, bypassing (removing) OBC from charging circuit, it can still prevent charger from working, assuming charger is functional? Interesting . . . how? . . .
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Unread 07-30-2013, 07:33 AM   #6
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Default Re: Ds obc

Good info
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Unread 07-30-2013, 08:20 AM   #7
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Default Re: Ds obc

Quote:
Originally Posted by Stevegrmich View Post
. . . so, bypassing (removing) OBC from charging circuit, it can still prevent charger from working, assuming charger is functional? Interesting . . . how? . . .
The bypass procedure above is only for the relay activation circuit of the OBC. The negative wire (black) goes from the back of the charger socket to the OBC, then thru an SCR inside the OBC before getting to the battery pack.
If the SCR is bad, the batteries will not charge even if the charger relay is activated.
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Unread 07-30-2013, 09:28 AM   #8
KCR
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Default Re: Ds obc

To then bypass the OBC one would run a wire from the negative on the charger plug to the negative battery terminal?
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Unread 07-30-2013, 09:50 AM   #9
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Default Re: Ds obc

Yes that in addition to the relay bypass should keep the charger running non-stop.
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Unread 07-30-2013, 10:28 AM   #10
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Default Re: Ds obc

Quote:
Originally Posted by Stevegrmich View Post
. . . so, bypassing (removing) OBC from charging circuit, it can still prevent charger from working, assuming charger is functional? Interesting . . . how? . . .
You are only bypassing one part of it... It's impossible to go totally around the obc since it's part of the charging circuit. I don't know the internals of the obc but I have replaced at least 100 obc that couldn't be bypassed
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