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Unread 04-26-2010, 10:45 PM   #1
Not Yet Wild
Tomberlin
 
Join Date: Jul 2009
Location: Iowa
Posts: 39
Default HELP me with Charging Issue!

I have a 2004 ClubCar DS that has ran perfectly until a month ago when I took it to get painted.

Now it will not charge longer than 2 minutes before turning off....

Before I tell you what appears to be my final options, here's what I've done:

1) Found two battery cables that were almost rotted thru and I replaced them.
2) Found a broken wire in the charger cord itself, fixed.
3) Company I bought cart from replaced my charger with a new one anyway.
4) Rebooted the OBC many times.


Now....

Company I bought the cart from (2 hours from home) took a hand held meter to diagnose the cart (they were the ones who found the two bad cables)...told me the batteries were fine and sent me on my way.

Incidentally, after they did that, I stayed there and watched MY charger charge up MY cart for 25 minutes...convinced it was fixed, I left and when I got home, problems started again...could not charge for more than two minutes and the orange warning light went on.

Heres my dilemma....

The dealer said they believe my OBC needs to be replaced at a four hour round trip drive, one hour wait and $194.00.

Local auto shop owner who's a golfer said he thinks it's just a bad battery, I need to buy a hydrometer, find the bad battery and swap it out for a new one.

I need cart fixed by Thursday...anyone here have an expert opinion?
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Unread 04-26-2010, 11:02 PM   #2
Cartsunlimited.net
 
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Join Date: Dec 2007
Location: Southern California
Posts: 64,079
Default Re: HELP me with Charging Issue!

I need cart fixed by thursday!??????? Oh Sorry I thought you were one of my clients .....

Dude, Get the hydrometer. Call the battery guy. Get a load test on those batteries and replace what needs replacing.... yeh you could still need an OBC... but we could jump your charger and make that tee time
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Unread 04-26-2010, 11:10 PM   #3
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Join Date: Jul 2009
Location: Iowa
Posts: 39
Default Re: HELP me with Charging Issue!

Quote:
Originally Posted by scottyb View Post
I need cart fixed by thursday!??????? Oh Sorry I thought you were one of my clients .....

Dude, Get the hydrometer. Call the battery guy. Get a load test on those batteries and replace what needs replacing.... yeh you could still need an OBC... but we could jump your charger and make that tee time
Ya know? When I typed in this part:
Quote:
I need cart fixed by Thursday.."
I chuckled and thought that I sounded like my customers who want their golf clubs repaired or created in some ungawdly time frame...LOL

I guess I deserve the teasing.....

BTW, thanks for the advice.
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Unread 04-27-2010, 08:24 PM   #4
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Join Date: Mar 2010
Location: Golf Car Capital of The World... Augusta, Georgia
Posts: 8,002
Default Re: HELP me with Charging Issue!

Quote:
Originally Posted by scottyb View Post
I need cart fixed by thursday!??????? Oh Sorry I thought you were one of my clients .....
Wow those people must range all the way from GA to CA. They're definitely over here in full force.
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Unread 04-27-2010, 08:27 PM   #5
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Default Re: HELP me with Charging Issue!

Quote:
Originally Posted by indacup View Post
I have a 2004 ClubCar DS that has ran perfectly until a month ago when I took it to get painted.

Now it will not charge longer than 2 minutes before turning off....

Before I tell you what appears to be my final options, here's what I've done:

1) Found two battery cables that were almost rotted thru and I replaced them.
2) Found a broken wire in the charger cord itself, fixed.
3) Company I bought cart from replaced my charger with a new one anyway.
4) Rebooted the OBC many times.


Now....

Company I bought the cart from (2 hours from home) took a hand held meter to diagnose the cart (they were the ones who found the two bad cables)...told me the batteries were fine and sent me on my way.

Incidentally, after they did that, I stayed there and watched MY charger charge up MY cart for 25 minutes...convinced it was fixed, I left and when I got home, problems started again...could not charge for more than two minutes and the orange warning light went on.

Heres my dilemma....

The dealer said they believe my OBC needs to be replaced at a four hour round trip drive, one hour wait and $194.00.

Local auto shop owner who's a golfer said he thinks it's just a bad battery, I need to buy a hydrometer, find the bad battery and swap it out for a new one.

I need cart fixed by Thursday...anyone here have an expert opinion?
You need to determine whether your charger is actually turning off... or dropping out.. By this I mean whether or not the car is actually telling to charger to turn off, or if the charger is malfunctioning and turning itself off. Watch the charger as it charges and listen to the charger relay inside the charger. If it clicks when it turns off, this means that the relay has lost power from the car and shut itself off. This would mean that the car has told the relay to turn off, In which case, I would definitely lean more toward a battery or OBC problem. If the charger is turning off based on ammeter readings, with no click... replace the charger relay. It's probably just dropping out for no apparent reason. Probably just old and worn out, the contacts inside the relay get dirty and corroded just as they do in older solenoids. Let us know what's going on.
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Unread 04-27-2010, 09:50 PM   #6
keg
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Default Re: HELP me with Charging Issue!

just a wild card, Ijust went thru a elec. mess on mine
Did you replace your main ground ? if so make sure you went thru the obc not around. turns out the obc knows if the cable is going thru. My charger would tun on then off 2 times. After I re-did the ground its been fine
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Unread 04-27-2010, 09:59 PM   #7
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Default Re: HELP me with Charging Issue!

Quote:
Originally Posted by TahoeDawgZ71 View Post
You need to determine whether your charger is actually turning off... or dropping out.. By this I mean whether or not the car is actually telling to charger to turn off, or if the charger is malfunctioning and turning itself off. Watch the charger as it charges and listen to the charger relay inside the charger. If it clicks when it turns off, this means that the relay has lost power from the car and shut itself off. This would mean that the car has told the relay to turn off, In which case, I would definitely lean more toward a battery or OBC problem. If the charger is turning off based on ammeter readings, with no click... replace the charger relay. It's probably just dropping out for no apparent reason. Probably just old and worn out, the contacts inside the relay get dirty and corroded just as they do in older solenoids. Let us know what's going on.
Hi David...I think you missed the line where I said:
Quote:
3) Company I bought cart from replaced my charger with a new one anyway.
So battery charger has been ruled out....
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Unread 04-27-2010, 10:03 PM   #8
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Join Date: Jul 2009
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Default Re: HELP me with Charging Issue!

Quote:
Originally Posted by keg View Post
just a wild card, Ijust went thru a elec. mess on mine
Did you replace your main ground ? if so make sure you went thru the obc not around. turns out the obc knows if the cable is going thru. My charger would tun on then off 2 times. After I re-did the ground its been fine
Good thought! But I did not replace the ground...however, my cart was working 100% until one weekend I did two things at one time I had the cart repainted and switched cart sheds.

After that weekend, the cart went to crap.

So I just GOTTA think that the painter, when he took apart the cart did something.
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Unread 04-27-2010, 10:36 PM   #9
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Default Re: HELP me with Charging Issue!

Quote:
Originally Posted by indacup View Post
Hi David...I think you missed the line where I said:

So battery charger has been ruled out....
I wouldn't rule it out for sure... I've taken new chargers out of the box and had to fix them before.
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Unread 04-27-2010, 10:38 PM   #10
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Default Re: HELP me with Charging Issue!

Quote:
Originally Posted by TahoeDawgZ71 View Post
I wouldn't rule it out for sure... I've taken new chargers out of the box and had to fix them before.
But don't ya think two different chargers being bad would be almost impossible?
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