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09 club car precident, has been sittibg a time batteries…

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09 club car precident, has...
09 club car precident, has been sittibg a long time batteries very low, but I got the charger to kick in, and cart did run yesterday. I continued charging overnight. This AM, charger off, and will not resume charging. Charger does click when plugged in. Cart does not move, reverse horn does not sound. Charge meter shows charge, and lights etc work.
Did I fry the obc? Or controller?
Thank-you,
MGM
Submitted: 2 years ago.Category: Electric Vehicles
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Answered in 13 minutes by:
2/12/2016
Electric Vehicle Mechanic: Curtis B., Other replied 2 years ago
Curtis B.
Curtis B., Other
Category: Electric Vehicles
Satisfied Customers: 31,840
Experience: Worked on fleet of various electric vehicles, golf carts, scissor lifts and electric booms.
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More likely a bad cable or connection at battery pack or to the charger connection. Do you have a voltmeter to check the batteries and voltage points? What is voltage where the charger would plugin? Should be close to battery pack, 36 or 48 volts. What does each battery test at? Any one battery or cable will kill the system and keep charger from coming on.

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Customer reply replied 2 years ago
Cart has a four battery 48 volt system. Three batteries at 12.4v. One I replaced this morning at 10.2. The replaced bat was at 8.3. All connections are good, as I said, lights work, charge level indicator shows good charge. No reverse horn. No cart movement in either f or r. No click in solonoid when pedal pushed. Im sure the charger timed out overnight, and shut itself off. Cart ran yesterday, but charge was low, so I continued charging overnight.
Thanks!
Electric Vehicle Mechanic: Curtis B., Other replied 2 years ago

What is voltage at the charger receptical?

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Electric Vehicle Mechanic: Curtis B., Other replied 2 years ago

Club Car will have a fuse in the wire to the key switch. Do you have 48 volts to key?

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Customer reply replied 2 years ago
I cant check now as batteries are out, and i have back plate off to check fuses etc, all OK .
Electric Vehicle Mechanic: Curtis B., Other replied 2 years ago

OK< Have you checked all the connections from charger connection to battery pack?

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Customer reply replied 2 years ago
All was good yesterday, charger clicks when contact made, so I,assume those connections ar OK as well. Reverse horn worked yesterday, nothing Today.
Electric Vehicle Mechanic: Curtis B., Other replied 2 years ago

Nothing from charger tells me there is a break in the primary circuit, the charger, through battery pack, back to the charger. Of course with the OBC on the Club Car, it can keep charger from coming on.

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Customer reply replied 2 years ago
My next step was to bypass the OBC. This should allow me to continue charging, but will it allow the cart to run? Im not real good with computers anyway.
Electric Vehicle Mechanic: Curtis B., Other replied 2 years ago

Yes, cart will run with OBC bypassed. But I would be checking the voltage at he charger and primary circuit, after you put batteries back in. Don't take it for granted! Something that was conned yesterday, is not connected today!

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Customer reply replied 2 years ago
I will bypass obc and put back together, then let you know. Thanks.
Electric Vehicle Mechanic: Curtis B., Other replied 2 years ago

OK> Thanks.

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Customer reply replied 2 years ago
Hello again Curtis.
Obc bypassed, voltage at charge pins and key switch 48. Still no signs of life, except lights come on and charge meter lights. No solonoid click, no reverse horn. Im about to check out f/r switch.
Customer reply replied 2 years ago
F/r switch ok, very simple, cant go wrong
Customer reply replied 2 years ago
Ive been working on carts for a long time. Sounds like primary circuit to me too, I just cant figure out where, unless it is in the controler, again a d"@&$d computer.
Electric Vehicle Mechanic: Curtis B., Other replied 2 years ago

What is voltage at the charger plug

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Customer reply replied 2 years ago
48 volts
Electric Vehicle Mechanic: Curtis B., Other replied 2 years ago

So charger should come on, and circuit is complete.

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Electric Vehicle Mechanic: Curtis B., Other replied 2 years ago

48 volts to foot switch from keyswitch, to engage the solenoid? No solenoid click, no voltage from foot switch?

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Customer reply replied 2 years ago
ok maybe, I didnt think of that one. Thanks
Electric Vehicle Mechanic: Curtis B., Other replied 2 years ago

OK>

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Customer reply replied 2 years ago
All pins except yellow show 48 v. Smehow the primary is not being energised. The reverse horn SHOULD sound when in R if power is coming through. Also the charger SHOULD start unless some higher authority is preventing it. All roads seem to lead to the controller, right?
Electric Vehicle Mechanic: Curtis B., Other replied 2 years ago

Seems to.

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Electric Vehicle Mechanic: Curtis B., Other replied 2 years ago

charger not starter!

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Electric Vehicle Mechanic: Curtis B., Other replied 2 years ago

If you remove charger cover, and jump the internal relay will the charger come an put out amps?

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Customer reply replied 2 years ago
Charger puts out full amperage when jumped. The fault is somewhere in the cart.
Electric Vehicle Mechanic: Curtis B., Other replied 2 years ago

OK< so we know it is capable of charging!

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Customer reply replied 2 years ago
My plan is to jump charger tomorrow and charge for a few hours whileI can watch it,to bring batteries up. Then??????
Electric Vehicle Mechanic: Curtis B., Other replied 2 years ago

O, bring batteries up to around 54 volts an see if it will do anything. Jump solenoid if it does nothing and see if cart will run with solenoid jumped.

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Customer reply replied 2 years ago
Good morning, still no joy. Solonoid will click when jumped, I cannot access it with all parts in place to see if cart will run. Everything is mounted to aluminum acces plate. A friend here said that clubcars wont run without horn in system. I jumped the connections this AM, still nada. Many wires enter the controller, no power comes out.
Electric Vehicle Mechanic: Curtis B., Other replied 2 years ago

Solenoid can click, and still not make the contact. You do have voltage into the controller? Just nothing out?

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Electric Vehicle Mechanic: Curtis B., Other replied 2 years ago

Cn you get meter leads to the solenoid? Does it have battery voltage to both sides? It should, and solenoid just makes the connection.

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Customer reply replied 2 years ago
I had to energise solonoid on both small leads to click, no voltage i did not jump large leads as tthe solonoid was doing that. Motor did not start, no power from controler I assume. Remember, cart did run the day before. With charger jumped and charging, I now get a fast beep from reverse horn, after a short charge. some warning I have not looked up in the charger instructions as I am replacing the wall of the work shop today, termites.
Electric Vehicle Mechanic: Curtis B., Other replied 2 years ago

OK> just don't take the solenoid for granted. It may not be closing and making the connection.

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Customer reply replied 2 years ago
Nothing happens anywhere, except, a click comes from a relay when key turned on. No other signs of life. Horn now sounds with rapid beep when charging with jumped charger. One battery still low, but total voltage around 50. Charger is type that needs obc which is bypassed, making jump necessary.
Electric Vehicle Mechanic: Curtis B., Other replied 2 years ago

OK, I would want to check voltage at the solenoid and jump it if it has battery voltage on the two large terminals.

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Customer reply replied 2 years ago
I tried to jump solonoid when I had everything out and reassembled nothing yellow lead goes to controler.
Electric Vehicle Mechanic: Curtis B., Other replied 2 years ago

Are you testing with a voltmeter?

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Electric Vehicle Mechanic: Curtis B., Other replied 2 years ago

Cart has MCOR, motor control regulator. It has two functions, one is to close solenoid, the other is to send signal to the controller.???

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Customer reply replied 2 years ago
im using a volt meter. I assume this cart has some sort of computer in controller, as LOTS of wires go in, not like earlier, and simpler controlers.
Electric Vehicle Mechanic: Curtis B., Other replied 2 years ago

Do you have battery voltage to both large terminals on the solenoid?

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