2007 DS Not Charging

cellaway1

I have a 2007 DS 48v with the 4 -12volt battery setup. I have the PowerDrive 2 charger. I have tried the charger on another cart and it works. I have also tried a PowerDrive 3 with no luck on my cart. I have jumped the grey sense fuse wire at the receptacle and can get the relay to click but it still does not charge. I have jumped the wires in the charger to bypass the OBC and still does not charge. I have tried 2 known good sets of batteries with the same results. I have been charging the 12 volt batteries individually which has been working but would like to get the PowerDrive charging the cart again. Battery pack voltage is usually 50.4 or so charging the individually.

I have a couple of questions. If the relay on the charger clicks only when the grey sense fuse is jumped is it still possible the charging receptacle can be the problem? Any other ideas?

BGW

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Stevegrmich

. . . check the fuse on back side of charger receptacle in battery area . . also, try WD40 on plug/receptacle, just in case . . .

cellaway1

thanks for the reply...checked the fuse on the back of the receptacle and it "looks" good, I am guessing that it would be broken if it wasn't right?

sprayed a little WD40 in there and still no charge

Fishing Dude

Sounds like broken red or black wire.

Stevegrmich

...provide a pic of your battery pack area . .

cellaway1

Sent from my XT901 using Tapatalk

Stevegrmich

. . . from manual . . .

3.1. Make sure the two nuts that secure the two 10-gauge black wires to the receptacle fuse assembly are tight.

3.2. Check the connections of the 18-gauge gray wire from the receptacle to the sense lead fuse, and from the sense lead fuse to the onboard computer gray wire (someone recently had a bad sense lead wire).

3.3. Remove the gray sense lead fuse and check it for continuity with a multimeter set to 200 ohms. The resistance should be less than 2 ohms.

. . . also, using a VOM, check continuity on receptacle fuse that "looks good" to make sure it IS good . . .

. . . have you attempted to do an OBC reset as shown in the "stickies"?

These are the simple checks before considering a possible OBC failure . . .

cellaway1

I checked the fuse assemble and everything is tight there, took it apart and all three wires are tightly secured to those silver connectors as well.

Checked the grey wire and it is intact on both ends. Is there anything else or any other way to test that sense lead wire?

Sense lead fuse tested good as well, even tried 2 other fuses in the yellow fuse holder and still no charge.

I have done the OBC reset with no luck. To check continuity on the recceptacle fuse does the charger need to be plugged in?

Sergio

The problem is most likely the SCR in the OBC. You have already tested the red and gray wires and pins thru the receptacle by jumping the sense wire and having the relay click on.
Unfortunately the current then flows thru the black wire, thru the SCR in the OBC before going to the batteries.
To make sure there is no breakage on the black wire, check continuity from the receptacle - (negative) pin to a point in the black wire closest to the OBC. You will need a insulation piercing probe or equivalent.

Fishing Dude

nope