95 Club Car 48v Stopped moving

[Sergio]

If that fuse on the Negative wire was blown, it would prevent the batteries from charging, but it would not prevent the charger relay from clicking.

I was referring to the sense wire fuse, part #9 in the picture below:

http://www.buggiesgonewild.com/attac...receptacle.jpg

[Sgt Minuteman]

Ok so I reset the OBC and the cart ran fine both ways. I just got my new replacement DPI Charger and will see if my cart charges. Keep your fingers crossed for me !

[Sgt Minuteman]

Ok got the replacement DPI Charger and nothing happens when I plug it in. So I disconnected it. It is apparently tripping something because now my cart won't move again and I will have to reset the OBC agai aND the cart works. .

[Sgt Minuteman]

Originally Posted by Sergio

As mentioned above, in order for the charging system to work properly, the model charger You bought would require a functioning OBC.

That may not be Your problem if the charger relay is not even clicking (no sound from the charger).

In order for the charger relay to click, You only need two things:

1) Positive wire from the pack positive to the charger receptacle.
2) Sense wire working and providing the negative side of the relay.

Make sure the shop connected Your wires back together the correct way.

Set your meter to 200vDC.

Measure the voltage from the Pack negative battery post to the positive socket of the Charger Receptacle.

You should get Pack Voltage, if not, make sure the positive wire from the charger receptacle is connected to the pack positive battery post.

If the first test is good, measure the voltage on the Charger Receptacle from the "Sense" wire socket to the "Positive" wire socket.

You should get about 5v less than pack voltage, if You get 0v, make sure the fuse on the sense wire fuse holder is good.

Ok I tested and did not get anything but a 1 on my mutimeter display when testing the voltage from the Pack negative battery post to the positive socket[ of the Charger Receptacle. Would it be the fuse inside that is bad? Should I just replace the whole recepticle? FYI the clear window fuse on top of recepticle looks intact.

Here is what my setup looks like..




Receptacle looks a little crusty...lol.

They gray receptacle wire is spliced into something is that ok?

My charger

[Sergio]

I think You had Your meter set wrong.

Make sure the meter is set to 200vDC and measure the pack voltage first to verify You are getting the correct reading.

If You get the correct voltage on the pack, please try those 2 readings again.

[Sgt Minuteman]

Originally Posted by Sergio

I think You had Your meter set wrong.

Make sure the meter is set to 200vDC and measure the pack voltage first to verify You are getting the correct reading.

If You get the correct voltage on the pack, please try those 2 readings again.

LOL Yes you were right had it on 200m. It read 49.8 at the recepticle.

the voltage on the Charger Receptacle from the "Sense" wire socket to the "Positive" wire socket is 47.7

Is it possible my batteries are not low enough to set off the DPI charger?
Could my OBC actually already be bypassed and this is what causs my cart to have to need reset?
If it was bypassed, would the reset procedure still be possible?
Sorry for so many questions. I am a newbie to this, but love working on this cart.

[Sergio]

The charger should come on at full current even if the batteries are fully charged.

According to Your readings it seems like the relay inside the charger should come ON.

Perhaps the relay is too quiet for You to hear it?

Disconnect the AC plug from the wall.

Set meter to continuity and place it on the charger AC plug blades.

When You plug the DC cord to the cart, You should get continuity on the meter.

Although from your description of the OBC locking out when you plug the DC cord, it sounds more like the OBC is bad.

I also noticed You don't have OEM cables, could the pack negative cable have damaged the OBC when someone ran the new cable through it?

[Sgt Minuteman]

Originally Posted by Sergio

The charger should come on at full current even if the batteries are fully charged.

According to Your readings it seems like the relay inside the charger should come ON.

Perhaps the relay is too quiet for You to hear it?

Disconnect the AC plug from the wall.

Set meter to continuity and place it on the charger AC plug blades.

When You plug the DC cord to the cart, You should get continuity on the meter.

Although from your description of the OBC locking out when you plug the DC cord, it sounds more like the OBC is bad.

I also noticed You don't have OEM cables, could the pack negative cable have damaged the OBC when someone ran the new cable through it?

OK I will try that.

The shop guy said they were able to charge it when they had it so I don't know. Looks like the original cable on the cart was used as it is still coated with mud...







I left the first charger I had on for an hour and it was not making noise and the meter on the front did not move. House plug and extension cord I am using are good. Ran my sander just fine. So you think I should change the OBC?

[Sgt Minuteman]

Originally Posted by Sergio

Disconnect the AC plug from the wall.

Set meter to continuity and place it on the charger AC plug blades.

When You plug the DC cord to the cart, You should get continuity on the meter.

Although from your description of the OBC locking out when you plug the DC cord, it sounds more like the OBC is bad.

OK so I set my meter to 200 Ohms and tested the AC plug for continuity and it read "1" when DC plugged into receptacle.

So does that indicate to you the OBC is bad?

Thank you so much Sergio for helping me with this, brother!

[Sergio]

I missed the comments between the pictures...

What is the gray sense wire spliced into? You need to follow that wire.