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Old 05-30-2014, 11:21 PM   #11
Sparky08
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Default Re: Club Car charging issues fuse pops out of charger

Did the entire kit work? I'm having the same problem and I only changed the rectifier. My problem is still happening.
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Old 05-30-2014, 11:32 PM   #12
jakesnake27
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Default Re: Club Car charging issues fuse pops out of charger

Welcome to BGW...
Circuit breakers can weaken as they pop, it is best to replace all three components.
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Old 05-31-2014, 08:06 AM   #13
Sparky08
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Default Re: Club Car charging issues fuse pops out of charger

Thank you
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Old 05-31-2014, 02:45 PM   #14
Garry2000DS
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Default Re: Club Car charging issues fuse pops out of charger

I have about the same problem, maybe I can get some help here.

I have a 2002 DS.
I have installed a kit with a rectifier, circuit breaker and relay from a well known ALL CART web site.

When I plug mine in, after about 5 seconds, the meter maxes out and the charger hums. After a couple more seconds, the fuse pops and the charger cuts off.

I did the voltage test as described in a post from ForBruce. He says to plug the charger into the cart (DO NOT PLUG THE CHARGER INTO 120V) and measure the voltage from the DC side of the rectifier. He says that it should be the EXACT same voltage that is read directly from the batteries, but didn't see what the problem was if they were not EXACT. My batteries shows 48.1 volts and the DC voltage at the rectifier was 37.2 volts.

I also bypassed the relay and measured the voltage at the plug and got ~48V but the meter did nothing.

Any help would be appreciated.
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Old 06-01-2014, 09:32 AM   #15
Garry2000DS
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Angry Re: Club Car charging issues fuse pops out of charger

A little more information;
I took a known good charger and it charged fine. I then bypassed the OBC by disconnecting the gray wire at the fuse and connecting a wire from the input side to the negative battery terminal and tried to charge again. The results was the same as before. So, I would think that this test indicates that the problem is not the OBC.

Anybody?
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Old 06-02-2014, 05:49 AM   #16
Stevegrmich
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Default Re: Club Car charging issues fuse pops out of charger

Quote:
Originally Posted by Garry2000DS View Post
A little more information;
I took a known good charger and it charged fine. I then bypassed the OBC by disconnecting the gray wire at the fuse and connecting a wire from the input side to the negative battery terminal and tried to charge again. The results was the same as before. So, I would think that this test indicates that the problem is not the OBC.

Anybody?
. . . if a KNOWN GOOD charger worked on your cart properly, then your OBC is functional . . . your charger is the issue . . . are you POSITIVE that the new rectifier was installed/wired properly?
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Old 06-02-2014, 07:38 AM   #17
Garry2000DS
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Default Re: Club Car charging issues fuse pops out of charger

Quote:
Originally Posted by Stevegrmich View Post
. . . if a KNOWN GOOD charger worked on your cart properly, then your OBC is functional . . . your charger is the issue . . . are you POSITIVE that the new rectifier was installed/wired properly?

The known good charger was a PowerDrive, not the PowerDrive2. I assume they would act the same.

Yes, I took lots of pictures before installing the kit. I did the diode test (test 4) in the battery charger service manual Between two of the pins the book called for .878 mine tested 1.24. I don't know if this is acceptable or not.
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Old 06-03-2014, 05:48 AM   #18
Stevegrmich
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Default Re: Club Car charging issues fuse pops out of charger

Quote:
Originally Posted by Garry2000DS View Post
The known good charger was a PowerDrive, not the PowerDrive2. I assume they would act the same.

Yes, I took lots of pictures before installing the kit. I did the diode test (test 4) in the battery charger service manual Between two of the pins the book called for .878 mine tested 1.24. I don't know if this is acceptable or not.
. . . any Power Drive charger can be used . . . if you are getting 1.24, read the last sentence of that test procedure:

"If any other reading is obtained, the rectifier has failed and must be replaced."

. . .
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Old 06-05-2014, 05:52 PM   #19
Garry2000DS
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Default Re: Club Car charging issues fuse pops out of charger

Well the guy that I bought the repair kit from sent me a replacement rectifier today. After installing, I get the exact same results. I am totally stumped. The only other thing to replace is the transformer. But When I jumper the relay, I get ~48V at the plug.

Any suggestions?
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Old 06-05-2014, 08:06 PM   #20
egartin
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Default Re: Club Car charging issues fuse pops out of charger

I purchased the complete kit and it corrected my problem.

Thanks Everyone.

Eric
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