Question on DS Charger

[Beerman24]

I have OBCs , pretty much free if you can use it, pay the shipping, I’m about to trash them.

[hrk]

Originally Posted by Beerman24

I have OBCs , pretty much free if you can use it, pay the shipping, I’m about to trash them.

May have take you up on one I'll PM you, the model number on mine is 101909901. Bought one off Amazon to test on the cart with the current diagnosis pointing at the OBC. That doesn't seem to be the issue, unless the new OBC is bad as well. Odds of two of them being bad?

Could the charging receptacle be bad, it was a bit difficult for the wife to get the charging cord to seat, I did check continuity all three holes showed continuity but it took a bit of wiggling around the meter wire before it worked.

Hate to keep tossing parts at the thing.

I guess I could order one, temp hook it up and see if that's the problem.


Summary:

Bought a OBC from Amazon, it has a 30 day return, and wanted to see if it made a difference. Has correct PN. Link

Some details of whats happened so far:

1) Tested my charger on another DS, it comes on after a few seconds of being plugged into the other cart.

2) Plugged my cart into a known working charger and it that charge will not come on.

3) Replaced all batteries, it was time anyway since the others had been run down too much and they were 5 years old this year. Batteries are Interstate 8V from Costco.

4) Removed old OBC, replaced with new OBC, checked connections, took pictures to confirm where all the wires should be.

5) Connected charger, it will not come on.

6) Continuity check with Red wire to charge port - it shows continuity
Also checked the other two - to the Fuse cap - and the third all show continuity.

7) Fuse in yellow holder is new and good.

8 ) charging receptacle was being difficult to get the charging cord connected, taking a bit more force than normal, wife couldn't get it to plug in properly, I thought the thing not charging for a while was her not plugging the thing all the way in....

[Beerman24]

Verify you have 48 volts from pack, main pos and main neg reading, this will tell us if you connected batteries right and if have a bad battery wire. Check the big fuse on the charge receptacle on the back side of it. Also definitely check the grey wire in the receptacle, that grey wire is basically what triggers the charger to come on, if it’s corroded in the receptacle, which happens often that could be the only issue.

[Beerman24]

Also if you want to do a test , can run wires, connect the grey to main negative and the black from back of charge receptacle to main negative as well. The red should be in main positive like normal. That by passes the OBC and should trigger the charger to come on. Note that this will only work if batteries have enough voltage, they should since you state they are new.

Remember this is just a test as the charger will NOT turn off on its own and could burn a cart up, that’s if it comes on for you.

Also if grey wire is corroded this test won’t work.

[Beerman24]

Another thought to: When you installed new OBC did you cut the black wire terminal off the old one and run the black wire that goes to the main negative through the hole in the OBC? Lots of people don’t run it through the hole in the middle of the OBC, and it has to be run through there.

[Beerman24]

And just so you know, the reason I have OBCs is I by pass them and get Summit 2 chargers. You can sell your old charger for $120-180 most likely if working and put towards a Summit. A guy local here sells the Summits for $180 that they pulled out of carts to do lithium upgrades so was a no brained for me to do the by pass.

[hrk]

Beerman, thanks appreciate all the information, the bypass is exactly what I was looking for, a way around the OBC to hopefully validate the issue.


That will be tonights project to run the two wires to the negative post.


Just checked the pack voltage, 48.1 across the pack, so wires are good
and total pack voltage as well.. Good to know.


The new OBC came with the black wire already installed through it, I checked online videos, before doing the swap which was a straight forward procedure


If it doesn't want to come on even with bypass it's got to be in the receptacle internally not connecting, there really isn't anything else.

At some point I may do as you suggested and go with the Summit 2 and dump the obc totally.

[Beerman24]

Yup, that grey wire is a “sense” wire so to speak, it senses voltage and if enough (I think has to be like 36v) it triggers the charger to come on. So if that grey wire is bad none of the tests will work.

[hrk]

Thats great information, would it be a good test to simply jump the grey to the last negative terminal, vs both black and grey, do one at a time, see if it's that wire only? or do both need to be jumped to go around the OBC

[Beerman24]

To eliminate the OBC , both have to be connected from the charge receptacle to the main battery neg. You will have to make wires and connect so you don’t cut the ones in your cart. Make sure to obviously make sure the originals are disconnected. Like I said this is just a test to trick the charger.