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Unread 01-30-2015, 04:57 PM   #1
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Default Charging issues on a 2002 Club Car DS 48v

Father-in-laws DS wont charge. Charger kicks on & hums but only in the lowest amp setting, looks like around 1-2amps. Runs like this for about 12hrs. Batteries are getting very weak - somewhere around 46v now - I know this is "empty" and should never go below 48v but it doesnt seem low enough to prevent the charger from kicking on to me.

We know the charger is all good. I took it apart and tested it per Club Car service manual and every component test passed. As a secondary test it was thrown on another 48V club car and it worked flawlessly.

Also the dash warning light wire has been cut - I can only assume because the previous owner couldn't get it to go off when he wanted to sell the cart

Is the dash warning light something worth hooking back up that will help aid us in figuring out whats wrong?
In my head the OBC seems like the culpret, is there a rock solid way to test this?
Is there any way to bypass it (even if temporarily) to get the battery pack voltage back up?
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Unread 01-30-2015, 04:59 PM   #2
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Default Re: Charging issues on a 2002 Club Car DS 48v

Try to jump the relay and see if it turns on
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Unread 01-30-2015, 05:11 PM   #3
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Default Re: Charging issues on a 2002 Club Car DS 48v

The OBC controls the charger current as it passes thru an SCR inside the OBC.

If the charger is working fine on another cart, just run the negative wire from the back of the charger receptacle directly to pack negative.

Later You can try resetting the OBC to see if the software was locked.

Edit: Keep an eye on the voltmeter and unplug the charger once it gets to 60v pack voltage.
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Unread 02-02-2015, 06:40 AM   #4
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Thanks Sergio! Will give it a shot.
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Unread 02-03-2015, 10:26 AM   #5
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Default Re: Charging issues on a 2002 Club Car DS 48v

The wire to the charger light on my 2002 was unplugged when I got it. I hooked it back up and have seen no negative affects.
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