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Unread 09-01-2016, 08:52 PM   #21
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Default Re: 2004 Club Car DS wont charge or move

Ok. The drilled one is unlikely to perform properly so if it stays in, then it's smart charger and bypass time.
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Unread 09-03-2016, 04:38 PM   #22
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Default Re: 2004 Club Car DS wont charge or move

Got a new relay today and my charger kicks on for about a min and then kicks back off . Any idea on what that could be
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Unread 09-03-2016, 05:02 PM   #23
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Default Re: 2004 Club Car DS wont charge or move

Are you still using the drilled out obc? If so that is 99.9% the likely cause.
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Unread 09-03-2016, 05:51 PM   #24
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Default Re: 2004 Club Car DS wont charge or move

Still using it but the charger reads pack voltage on the relay so it's sending that back to the charger making me think it's good
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Unread 09-03-2016, 07:37 PM   #25
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Default Re: 2004 Club Car DS wont charge or move

Now when I jump it the charger does the same thing
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Unread 09-03-2016, 07:56 PM   #26
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Default Re: 2004 Club Car DS wont charge or move

That statement doesn't make sense - how are you jumping the relay? Is it like THIS thread/picture (click on picture to enlarge)? Also, what is the current pack voltage?
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Unread 09-03-2016, 07:59 PM   #27
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Default Re: 2004 Club Car DS wont charge or move

Sometimes its better to back up and start over...

What is the voltage of each battery and what is your overall pack voltage? I've got a hunch that something is still wrong there.

Attached is a picture for bypassing the circuits in the charger to troubleshoot and/or force charge. You will also need to cut and reroute the black negative wire coming from the charge port and attach it directly to the main pack negative.

Once you can truly force charge without the OBC in the equation will you be able to figure out if a charger, cord, plug, OBC etc is your issue.

As to drilling the OBC for a bigger cable while it has been done with success before I'm the only person I KNOW to have done it with success.
Attached Images
File Type: jpg Charger Jumper.jpg (188.4 KB, 0 views)
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Unread 09-04-2016, 08:13 AM   #28
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Default Re: 2004 Club Car DS wont charge or move

Okay so I switched my new relay out for my old one and jumped it again to get the charger back charging. When I started I was getting a pack voltage of 50.8 about an hour into charging when I turned the charger off I was getting a pack reading of 49.2 I don't really understand the drop in voltage?
Battery voltage as of now is ;
1- 8.2
2- 8.1
3- 8.1
4- 7.8
5- 7.6
6- 8.5

Last edited by boonesbuggies; 09-04-2016 at 09:41 AM.. Reason: left something out
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Unread 09-04-2016, 10:23 AM   #29
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Default Re: 2004 Club Car DS wont charge or move

Before any more troubleshooting I recommend you leave the charger on until the pack (while charging) reads at least 60v. You can even go to 64 volts for better equalization. It may sound scary but it will really benefit that pack. This may take 10 hours or more - please be patient. Those batteries have sustained some damage due to severe undercharge (thus the variation between them) so before continuing your work - you need to equalize and stabilize them so no further damage occurs. Once they are a bit more stable you can carry on troubleshooting. Make sure the distilled water level is just over the lead plates inside - but not higher than 1/4" above the plates.
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Unread 09-04-2016, 12:31 PM   #30
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Default Re: 2004 Club Car DS wont charge or move

Charge those batteries for at least 16 hours, for the most part those reading are near death...
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