Simple Test for OBC

[Aflyer]

Hi Guys,
I am helping my neighbor diagnose a no charge condition on his 2008ish Club Car DS. It has 4 12 volt battery's, same as my 2006.

Neither of our chargers will charge his cart, they both work on my cart. Battery's are manually charged to 49 volts on his cart, but charger will not kick on.

First checked all connections, cleaned up 2 that were marginal.

Tried to do the OBC reset, but got no reverse buzzer at all.

Checked the threads, and I can't find any instructions to test the OBC, can you post the testing steps for me?

Thank you,
George

[Kashmir]

http://www.buggiesgonewild.com/elect...excel-obc.html

[Aflyer]

Ok I can go red that thread, but is that the best or easiest way to test it?
Thank you,
George

[Kashmir]

There are two wires you can jump to test it. Not sure which ones, but I am pretty sure the procedure is in that thread.

[jjance]

Usually the answer to this question is that you left the small #10 ga red wire off the #1 battery positive post. Forgot don't worry about the reverse buzzer. That part never works.

[Aflyer]

Originally Posted by jjance

Usually the answer to this question is that you left the small #10 ga red wire off the #1 battery positive post. Forgot don't worry about the reverse buzzer. That part never works.

Thank you for the information.
We did find that small red wire to have a corroded terminal lug, but that has been replaced making no difference at all.
The cart runs, just will not charge, thus my request for methods to test the OBC.
George

[jjance]

The only way to test it is to replace with known good. But you need to verify that everything is hooked up correctly or it could turn into an expensive fishing trip.

[Aflyer]

Thank you for the post.

I have done the bypass test, the charger solenoid clicks but still not charging.

Still not sure what the problem is or what to test next.

Open for input.

Thank you,
George

[Sergio]

Make sure the AC outlet You are plugging the charger has Power.

You can make a few quick voltage tests to determine the charging problem:

Set the meter to DC Volts (200v scale if not auto-scale).


Measure from Positive Socket on the charger receptacle to Pack Negative.

You should have pack voltage.

If Not, make sure the 10ga red wire from the charger receptacle is connected to pack positive battery post.

Measure from Positive Socket on charger receptacle to Sense Wire Socket on the charger receptacle.

You should have about 42v (this can vary depending on your meter's impedance).

If Not, check the sense wire connection (and inline fuse if available) on charger receptacle.

If sense wire is good, the OBC activation circuit has failed.

Measure from Pack Positive to Negative Socket on the charger receptacle.

You should have a few volts less than pack voltage.

If Not and the cart is a DS, check the charger receptacle fuse on the negative wire (#6 on diagram below):

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

Otherwise the SCR inside the OBC that controls the charging current has failed.

If all of those voltages are OK and the charger relay is not clicking once You plug the DC cord into the cart, the issue is on the charger side of the relay circuit (DC plug, cable or wiring connections).

[Aflyer]

Originally Posted by Sergio

Make sure the AC outlet You are plugging the charger has Power.

You can make a few quick voltage tests to determine the charging problem:

Set the meter to DC Volts (200v scale if not auto-scale).


Measure from Positive Socket on the charger receptacle to Pack Negative.

You should have pack voltage.

If Not, make sure the 10ga red wire from the charger receptacle is connected to pack positive battery post.

Measure from Positive Socket on charger receptacle to Sense Wire Socket on the charger receptacle.

You should have about 42v (this can vary depending on your meter's impedance).

If Not, check the sense wire connection (and inline fuse if available) on charger receptacle.

If sense wire is good, the OBC activation circuit has failed.

Measure from Pack Positive to Negative Socket on the charger receptacle.

You should have a few volts less than pack voltage.

If Not and the cart is a DS, check the charger receptacle fuse on the negative wire (#6 on diagram below):

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

Otherwise the SCR inside the OBC that controls the charging current has failed.

If all of those voltages are OK and the charger relay is not clicking once You plug the DC cord into the cart, the issue is on the charger side of the relay circuit (DC plug, cable or wiring connections).

Sergio,
I have checked and believe all readings are as you stated they should be in each of the measurements above, how ever I will go through it once more in the morning. I have also tested the charger receptacle fuse, although I did not unbolt it to test continuity. Would that give me a faulty test result?

As you state in your last sentence, "the issue is on the charger side of the relay circuit... But that does not explain why two chargers both work on my cart, and neither one of them work on the neighbors cart. Both are DS IQ carts, one 2006 one 2007.

I will also try both chargers again in the morning.

Thank you,
George