New batteries,OBC,charger - 2001 Clubcar still won't charge

[jamesd32909]

2001 Club Car 48V. was not taking a charge. tested the batteries and they were bad - would not take a charge.
Replaced with new batteries.
Still would not take a charge.
Reset the obc.
Nothing.
Local golf course cart mechanic said it was the obc.
I replaced a Lester 21065 with a Lester 27145.
Ordered from the CartBarn (GREAT people by the way). Travis and Mark out there assured that the new OBC was compatible.
Installed new OBC.
Still would not take a charge.
I troubleshooted the Lester charger using Cartbarns phone help.
The charger was definitely shot.
Ordered a new Lester charger.
Hooked it up.
Still nothing.
The batteries will not take a charge and the charger doesn't even click on.


Jim Palm Bay Fl

[scottginfla]

so what does your battery pack read as far as voltage? and each battery by itself?

[Stevegrmich]

. . . first thing(s) to check are the:

1. Fuse on back side of charger receptacle, enclosed in glass.
2. Inline fuse (sense fuse, gray wire) on back side of charger receptacle.

. . . that's your starting point . . .

[Speedchaser]

Did you install the ne bats correctly? Do what Scott said and check total pack voltage and each bat individually, then you will know if it is hooked up right.

Maybe look into a dpi charger setup, thats what I did.

[jamesd32909]

Hey ScottginFLA- Thanks - voltage across the entire pack is 49.5V. Each battery is reading 8.2 to 8.3

[jamesd32909]

Hey Stevegrmich.....
Fuse on back of chrger receptacle is fine.
In-line fuse in yellow holder coming out of chrager receptacle is fine.

Hey Speedchaser.....
the batts are hooked up correctly and individual voltage is 8.2 to 8.3 - total pack voltage is 49.5

[Golfdog]

With a new OBC and Charger if the relay in the charger does not click closed when you plug in the charger to the cart then the OBC is not communicating with the charger. The two things I would look at are 1 the continuity of the red wire from the controller to the OBC via the 3 or 6 pin connector, that provides power to the OBC and 2 the continuity of the grey wire from the yellow fuse behind the car socket to the relay in the charger. The car charger socket can be problematic and I would remove it, open it up and check all three sockets.

[dave*m]

Simple thing to check but are both red wires connected to the main positive? Did you put the computer in the right way?If everything else is right then do a voltage test to see if there is a drop somewhere.

[jamesd32909]

Hey Dave*m
both red wire are connected to the main positive. OBC is installed correctly according to schematics. No drop in voltage anywhere.

Hey Golfdog...
great suggestion. I will test both wires for continuity and remove the charger receptacle and check the pins for looseness, etc. Not tonite, however... Bronchos are playing in a few minutes. Will get back with you all tomorrow.
YOU GUYS ARE GREAT!!!! (smart, too...)

Jim
Palm Bay FL

[jamesd32909]

HEY GOLFDOG and everyone that has helped!!!!!!!!!!!!!!

The grey wire had a broken solder connection. I disassembled the receptacle.Cleaned and soldered the grey wire to the pin. Charger came on immediately!!!!

You guys are GRRRREATTT!!!!!!!!!!!!!!!!!!!!

If you are ever in Palm Bay FL = I owe you a boat ride on the Intercoastal.

Jim
Palm Bay FL