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Unread 08-31-2016, 12:55 PM   #1
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Default 2004 Club Car DS wont charge or move

I haven't worked on many CC's but neighbor is wanting me to look at his. It was a great running 2004 DS and he replaced the batteries and now she's dead. I personally haven't seen it yet but he said when he replaced the batteries he also did the cables and the cable that goes into the computer ( I assume one goes into the side on the controller?) the cable wouldn't fit into the hole so he drilled the hole out a little bit. Now he said the charger kicks on for about 45 secs and goes back off. Had the charger looked at and its good. But the cart hasn't moved since. Any insight would be appreciated I have never looked under the seat of an electric DS and was wondering if a cable really goes into the controller instead of on the outside like a EZGO.
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Unread 08-31-2016, 01:02 PM   #2
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Default Re: 2004 Club Car DS wont charge or move

Quote:
cable wouldn't fit into the hole so he drilled the hole out a little bit
He's killed a device known as the obc, which measures and manages charging - the charger can't function properly without it. It's toast - drilled ones can't be fixed. Contact Revolution Golf Cars (HERE) for a OEM replacement. While ordering, the owner of Revolution can advise you how to make a thru-obc-stud which people generally use when installing bigger cables. HIDE THE DRILL FROM YOUR NEIGHBOR!
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Unread 08-31-2016, 01:33 PM   #3
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Default Re: 2004 Club Car DS wont charge or move

Or, if you want tp make an improvement, bypass the OBC and change out charger, New batteries will probably last longer.
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Unread 08-31-2016, 01:56 PM   #4
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Default Re: 2004 Club Car DS wont charge or move

How do you by pass it ?
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Unread 08-31-2016, 08:23 PM   #5
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Default Re: 2004 Club Car DS wont charge or move

I have the cart at my house now and it attempts to move in reverse and forward . Also he told me the charger had been check out and it's good, but doesn't do anything
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Unread 08-31-2016, 08:43 PM   #6
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Default Re: 2004 Club Car DS wont charge or move

The OBC tells the charger when to charge and for how long. The charger doesn't have any input from a dead OBC.

Suggestion- instead of replacing the OBC ($200 + or -) use that money towards a DPI charger ($285), by-pass the OBC, and sell the existing charger to recoup some of the costs.


.
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Unread 09-01-2016, 04:42 PM   #7
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Default Re: 2004 Club Car DS wont charge or move

OBC didn't change a thing looking into the charger now...
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Unread 09-01-2016, 04:50 PM   #8
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Default Re: 2004 Club Car DS wont charge or move

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he replaced the batteries and now she's dead
Look for batteries mis wired (backwards to one another, and not really in series), or a (forgotten) disconnected charging wire between the charging socket and the main pack positive battery terminal. These are two common issues when DIY batteries are replaced.
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Unread 09-01-2016, 05:22 PM   #9
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Default Re: 2004 Club Car DS wont charge or move

Everything looks right and like I said the back up buzzer works and it tries to work in forward and reverse just don't quite take off. How do you go about checking the charger ?
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Unread 09-01-2016, 05:26 PM   #10
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Default Re: 2004 Club Car DS wont charge or move

I predict bad controller.
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