2003 club car DS issues.

[NoleFan4Ever]

Ok, for obvious reasons, do not try to charge again until you have verified the correct wiring and battery configuration. If BBBHC's PM does not correct your issue, post some pics so we can try and help.

[buckeyejudge]

Heres what I dont understand. When I first put the batteries in, and after I replaced the fuse, it ran, just slowly. So I think the wiring should be ok. It only went kapoot when I first plugged the charger in a week ago. What should I check specifically?

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[LabRat]

I had a cart many years ago, that had similar smoking charger issues, it probably not you case but a rebuilt controller & charger fixed that problem

[buckeyejudge]

Originally Posted by LabRat

I had a cart many years ago, that had similar smoking charger issues, it probably not you case but a rebuilt controller & charger fixed that problem

The charger is not smoking, but something in the cart smokes each time I plug it in. The cart ran fine (slow, but fine) before I plugged it in to charge it.

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[Fairtax4me]

When you connected the black and grey the second time and the black wire fried, was the charger plugged into the cart at that time?

It’s very difficult, but not impossible to have a dead short at or near the charge receptacle, but it’s more likely to have a short or incorrect wiring inside the charger, or have shorted wiring in the charge cord or plug.

At this point either the OBC is damaged, or something is not wired correctly in the cart. And it’s also possible something the charger is not right, but that depends if it was plugged into the cart when the wires fried.

At The charge receptacle the black wire comes out, goes to the big clear fuse holder, then another black wire runs back to the OBC. Does your melted wire come from the fuse? Or did you bypass the fuse for testing?

Red wire should come from the receptacle and run over to the pack main positive terminal. You should measure 48v here (red meter probe in the receptacle socket, black probe on the main pack negative post).

[buckeyejudge]

So my question is now, can we bypass the OBC and see if the cart will still run? I can charge the batteries with another charger for now...I just want to make sure the cart still works.

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[NoleFan4Ever]

You can bypass it BUT, you need to jumper the Blue and the White wires together that are on the cart side of the harness. This will give your controller power to prevent Lockout.

[buckeyejudge]

Originally Posted by NoleFan4Ever

You can bypass it BUT, you need to jumper the Blue and the White wires together that are on the cart side of the harness. This will give your controller power to prevent Lockout.

What about the black & the grey from the charge port? If I'm not worried about charging right now, what do I do with those?

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[NoleFan4Ever]

If you are not going thru the charge receptacle, you can leave it for now until you decide what you will do. If you are going to fully bypass it and remove it, then you can remove it all. I use a 110v plug in my old receptacle.

[buckeyejudge]

Ok, so I jumped the blue & white wires and it now drives. So what does that mean? My OBC must be bad?
Should I replace the OBC and keep the stock charger?
Or bypass it and get a new charger?
What would you do?



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