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Unread 06-26-2014, 01:31 PM   #1
Gone Wild
Club Car
 
Join Date: Jun 2014
Location: Motown
Posts: 163
Default 03 club car won't charge

i've had my 03 club car cart for 3 yrs, found this site when it wouldn't charge before.
last time it was the diode pack that burned up.

my cart won't charge again...
i tried to reset the obc according to this post i read by crash test dummy
i had to remove the picture links because i can't post links for 7 days

Quote:
Originally Posted by crash test dummy View Post
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
• Press the throttle pedal down (hold it to the floor)

The reverse buzzer will sound (sometimes) and go off in about 30 seconds.
Leave the cart like that for 5 min to cause the OBC to reset.
After 5 min release the throttle pedal

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

if charger will not come on do a OCB by pass


OBC bypass
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 06-26-2014, 01:37 PM   #2
Gone Wild
Club Car
 
Join Date: Jun 2014
Location: Motown
Posts: 163
Default Re: 03 club car won't charge

nothing changed after doing the above proceedure
i did the obc bypass with no results and then opened the powerdriver2 to bypass the relay.
i have no hum and nothing on the charge meter

my cart is an 03 ds-iq, i believe from the serial number AQ0322
it is 48 volt, has a toggle switch for for/rev and has powerdriver2 charger
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Unread 06-26-2014, 01:39 PM   #3
Gone Wild
Club Car
 
Join Date: Jun 2014
Location: Motown
Posts: 163
Default Re: 03 club car won't charge

i will also read the powerdriver2 manual to see if i have bad diodes again
(building my post count so i can post links and pics )
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Unread 06-26-2014, 01:40 PM   #4
Gone Wild
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Join Date: Jun 2014
Location: Motown
Posts: 163
Default Re: 03 club car won't charge

any ideas what else i should check?
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Unread 06-26-2014, 01:45 PM   #5
Gone Wild
Club Car
 
Join Date: Jun 2014
Location: Motown
Posts: 163
Default Re: 03 club car won't charge

i disconnected the reverse buzzer 3 yrs ago, hopefully that didn't affect the obc reset
i left the throttle wot for 10 min just incase
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Unread 06-26-2014, 02:22 PM   #6
Epb
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Join Date: Mar 2012
Location: Katy, Tx
Posts: 1,019
Default Re: 03 club car won't charge

have you checked the internal fuse/breaker of the charger? Have you checked the capacitor (pull leads off first)?
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Unread 06-27-2014, 12:36 PM   #7
Gone Wild
Club Car
 
Join Date: Jun 2014
Location: Motown
Posts: 163
Default Re: 03 club car won't charge

not sure my charger has a capacitor, didn't see one in there.

unplugged and re-plugged everything i could unplug on the motor controller
then with the 48 volt relay bypassed today the charger is working today.
yesterday before un/re-plugging everything i was getting 12v on the black lead on the charge receptacle and 36v on the red lead.
now i have 0 and 48.

are the charger rebuild kits on ebay any good?
all i think i need is the relay, but a new diode pack laying around wouldn't hurt.
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Unread 06-27-2014, 02:01 PM   #8
Epb
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Join Date: Mar 2012
Location: Katy, Tx
Posts: 1,019
Default Re: 03 club car won't charge

I read others had success with the rebuild kit. Sorry for mentioning capa itor i was recently repairing a friends charger and it has one (its old) thanks for being cool about it. For 30$ its worth the try so you dont have to bypass anything. I did the bypassing for a year and finally bought a dpi. My issue was the obc and i wasnt going to spend 160$ for a charging control box that seems to cause problems per many threads here.
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Unread 06-28-2014, 02:03 PM   #9
Gone Wild
Club Car
 
Join Date: Jun 2014
Location: Motown
Posts: 163
Default Re: 03 club car won't charge

i ordered the ebay rebuild kit: rectifier, breaker and relay for $26
if this doesn't work i'll ebay the charger and get the DPI Accusense Battery charger that bypasses the obc
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Unread 06-30-2014, 01:56 PM   #10
Not Yet Wild
Club Car
 
Join Date: Jun 2014
Location: Indiana
Posts: 3
Default Re: 03 club car won't charge

Will my 2002 Club Car have an OBC? (I am new to the carting world)
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