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Unread 08-29-2009, 12:57 AM   #1
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Default 48V club car w/new batteries not charging

I got a 98 club car 48V a couple of weeks ago and was having battery charging problems. They were original batteries so I just replaced them. I also replaced all the battery cables and the cables going back towards the motor with 4ga welding wire cable. I put them in today and they will still not charge. It charges for a few minutes and then the charger shuts off and the orange light on the dash lights up. Any ideas as to what is wrong now? It has the powerdrive charger.
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Unread 08-29-2009, 01:04 AM   #2
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Default Re: 48V club car w/new batteries not charging

Some gurus will give you some good info shortly, but the first thing they will ask is the battery voltage, which is a requirement for diagnosis. Be prepared.
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Unread 08-29-2009, 01:11 AM   #3
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Default Re: 48V club car w/new batteries not charging

What charging problems were you having to begin with?
Sounds like an OBC problem.
What batteries did you install?
What is your voltage across the pack? From main pos. to main neg.?

Last edited by bioniccartsandcustoms; 08-29-2009 at 01:16 AM.. Reason: forgot...
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Unread 08-29-2009, 01:13 AM   #4
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Default Re: 48V club car w/new batteries not charging

Also, when you replaced the wiring, did you replace the main negative cable going to the controller? If you did, is it still going through the computer? If its not, This will cause the same symptoms your describing.
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Unread 08-29-2009, 08:53 AM   #5
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Default Re: 48V club car w/new batteries not charging

I was having the same problem as now where it charges for a while and then shuts off and the orange light comes on. Each battery is around 8.3. The whole pack is 50. I put in Trojan 875s. I replaced the wires going to each battery and both wires going back. The negative goes to a silver box, the positive goes to a cellanoid I think. This is my first cart and I really know nothing about it. Thanks for the help.
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Unread 08-29-2009, 11:23 AM   #6
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Default Re: 48V club car w/new batteries not charging

Quote:
Originally Posted by club98 View Post
I was having the same problem as now where it charges for a while and then shuts off and the orange light comes on. Each battery is around 8.3. The whole pack is 50. I put in Trojan 875s. I replaced the wires going to each battery and both wires going back. The negative goes to a silver box, the positive goes to a cellanoid I think. This is my first cart and I really know nothing about it. Thanks for the help.
When the wire comes off the main neg battery, it should pass through a small hole in the OBC before going to the silver box, Which is the controller. If it doesn't go through the OBC then the charger will not stay on.
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Unread 08-29-2009, 01:20 PM   #7
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Default Re: 48V club car w/new batteries not charging

The cable won't fit through the hole. Do you have to not put an end on the cable until it is through the hole? I bought some nice 4ga wires with ends on already. What does going through the hole do for you?

I was having the light/not charging problem before I replaced the batteries and the cables and the old cable WAS going through the hole.
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Unread 08-29-2009, 02:22 PM   #8
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Default Re: 48V club car w/new batteries not charging

You will have to cut the lug off the wire then replace the lug on the otherside of the OBC.

The OBC"reads" voltage from the cable. I suggest you use a combination solder/crimped lug to replace.

Don't mess with the size of the hole, etc. as you will cause a lot of $$$ hurt.
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Unread 08-29-2009, 02:23 PM   #9
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Smile Re: 48V club car w/new batteries not charging

I just had the same issue with my new 4ga cables.

I cut the end off the new cable, ran it thru the sensor device and attached a new end, crimped, soldered and put shrink wrap on, and attached it to the controller. So the cable runs from the negative of the last battery in the string, thru the sensor and to the controller.

From what I have read, you GOTTA run the ground thru the sensor or the cart won't like you. It won't run or charge correctly.

Have fun ! Dave
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Unread 08-29-2009, 02:40 PM   #10
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Default Re: 48V club car w/new batteries not charging

Some guys who didn't want to cut and repair the cable end simply ran both the new and old cable from the battery to the solenoid with the old one running thru the OBC so it could read pack voltage
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