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Unread 10-13-2010, 10:49 PM   #1
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Join Date: Oct 2010
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Default 48V charger won't stop charging

Hi. My 96 DS won't cycle the charger any more. Already replaced the charger relay and see that the fuse between the OBC and charger plug is smoked. Bypassed it momentarily with a larger (30A) fuse. Charger relay clicks on as soon is charger is plugged into cart. Charger meter shows about 15A and never cycles, never drops much. It charges batteries and cart runs OK. Reset OBC a few times and battery meter comes back to full, then drops with use but never comes back full after charging as above. Is there a procedure to test the OBC or does it just need to be replaced?
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Unread 10-13-2010, 11:18 PM   #2
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Default Re: 48V charger won't stop charging

Welcome to BGW, Bill... are you talking about the fuse in the yellow inline holder?
That is a 3/8th amp fuse. Have you tried the obc bypass test?











OBC bypass & Test =
The black wire coming out of charge receptacle has a yellow fuse holder, open it up and connect a jumper from the end coming out of receptacle to the negative on Battery 6 or the last one in series. Plug in the charger if it comes on your OBC is most likely TOAST.
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Unread 10-14-2010, 06:07 AM   #3
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Default Re: 48V charger won't stop charging

scottyb,

Thanks for the quick post. Yes it was the fuse in the yellow inline holder. I didn't do exactly the OBC bypass test you describe. I did essentially replace the blown fuse with a wire but didn't put the other end of the jumper to the low end of the battery stack and it charges fine, but does turn on the relay as soon as the charger is plugged in to the cart. Will surely give that bypass test a try at my next chance. Do you have any suggested OBC sources? Internet search shows prices between 200 and 240 generally. It looks like I will want to pull the old one to confirm the part number before buying a replacement. The OBC was replaced a few years back. Do they fail often? Thanks again.
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Unread 10-14-2010, 01:11 PM   #4
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Default Re: 48V charger won't stop charging

1995-1996 model OBC's factory units were not the best but modern replacements seem to have no problems. Often the problem you describe is weak battery cells that dont allow voltage to reach OBC cut off point ( above 50.96 Volts with digital hand held meter "NOT DASH GAUGE" and 1.277 gravity on all cells?)
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Unread 10-14-2010, 02:21 PM   #5
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Default Re: 48V charger won't stop charging

I recently replaced a 3yr old OBC. I asked the same question. It seems it is not common but it does happen. You need the number off of the back side of the unit to match it up.... contract member Tdawg re OBCs. You will find him in the Electric CC section daily.
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