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Unread 02-05-2012, 04:51 PM   #1
Gone Wild
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Default 1995 Club Car DS 48 volt Series Charger problems

Ok, I am usually an EZGO guy but I found this cart yesterday at a great price so I bought it. I don't know much history about the cart except that the guy told me the batteries are 1 year old and the charger will not turn off on it's own. I brought it home, checked the water in the batteries, and plugged it in to charge. That was at 8:00 last night and the charger went to 17 amps. I checked it this morning at 9:00 and the charger was still running and showed 4 amps. I went to church and when I got home at 2:00 I looked at it again and it was still charging and still on 4 amps. I unplugged to charger and started looking at the battery cables and a few of them were corroded badly. One of them pretty much broke off in my hand when I pulled on it. I have been reading and from what I understand there is supposed to be an on board computer that shuts the charger off after 16 hours regardless of the state of the batteries. So I guess my question is this.... would the bad cables cause a problem with the charger? Should I replace all the cables and try charging it again or is the definitely something wrong with the charger/OBC? Any help with this would be appreciated, this club car is a different beast than I am used to working on.

Thanks in advance!
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Unread 02-05-2012, 06:32 PM   #2
Gone Wild
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Default Re: 1995 Club Car DS 48 volt Series Charger problems

Just a little more info...

I pulled all the batteries off the cart so I could clean the battery tray. About 3 hours after pulling the batteries I checked the voltage with my DMM. All 6 batteries showed exactly the same @ 8.59 volts. Is that good?
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Unread 02-05-2012, 08:07 PM   #3
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Default Re: 1995 Club Car DS 48 volt Series Charger problems

yes that is good, change any cables you arn,t sure of and clean the rest than put the charger on and let it go until you get to the 16 hours....see if it shuts off if not you can open the charger to see if for some reason they have the relay jumped or bypassed so charger won,t shut off ( you can do that with the charger ) if all is good in the charger then yes it could be the OBC which on a 1995 its very rare for OBC to go bad that way but they do...............if you want to be certain you can try the charger on another C.C. 48 volt cart and see if it shuts off that way your 100% its your OBC.....................................
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Unread 02-05-2012, 08:15 PM   #4
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Default Re: 1995 Club Car DS 48 volt Series Charger problems

Quote:
Originally Posted by shadowman View Post
yes that is good, change any cables you arn,t sure of and clean the rest than put the charger on and let it go until you get to the 16 hours....see if it shuts off if not you can open the charger to see if for some reason they have the relay jumped or bypassed so charger won,t shut off ( you can do that with the charger ) if all is good in the charger then yes it could be the OBC which on a 1995 its very rare for OBC to go bad that way but they do...............if you want to be certain you can try the charger on another C.C. 48 volt cart and see if it shuts off that way your 100% its your OBC.....................................
Thank you for the reply!

Now that you mention it, the guy I bought it from said that when he got it the charger would not come on at all so he took it apart and did something to get it to come on. I did not ask him what he did to get it to come on. Maybe he jumped the relay at that time? I will check that out in the morning and see if it's obviously jumpered.
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Unread 02-05-2012, 09:44 PM   #5
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Default Re: 1995 Club Car DS 48 volt Series Charger problems

Well, I pulled the cover off the charger and there is no relay present at all. I do see where he used a wire nut to connect two wires together so I would assume that's where the relay would go? Is there a wiring diagram anywhere for this charger? I looked at the sticky but the link to the manual has been deleted. Thanks for any help.
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Unread 02-05-2012, 10:05 PM   #6
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Default Re: 1995 Club Car DS 48 volt Series Charger problems

I found the diagram and ordered a new relay for the charger. Thanks for the help and hopefully this will get me fixed up.
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Unread 02-05-2012, 10:14 PM   #7
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Default Re: 1995 Club Car DS 48 volt Series Charger problems

One more question. What is the item I circled in the diagram? Is this an internal part of the relay or something I need to find and add back to the new relay? Sorry for my ignorance.
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Unread 02-06-2012, 06:47 AM   #8
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Default Re: 1995 Club Car DS 48 volt Series Charger problems

Diode . . ??
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Unread 02-06-2012, 08:08 AM   #9
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Default Re: 1995 Club Car DS 48 volt Series Charger problems

is that a small black thing with 2 wires connected in it? if thats it thats where they would have taken a wire and jumped it for charger to come on.......and if thats the case it won,t shut off.........if they did the bypass its cause the OBC is bad and won,t let the charger turn on, much more common on a 1995.............................
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Unread 02-06-2012, 09:51 AM   #10
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Default Re: 1995 Club Car DS 48 volt Series Charger problems

Quote:
Originally Posted by shadowman View Post
is that a small black thing with 2 wires connected in it? if thats it thats where they would have taken a wire and jumped it for charger to come on.......and if thats the case it won,t shut off.........if they did the bypass its cause the OBC is bad and won,t let the charger turn on, much more common on a 1995.............................
No, there is not a relay present at all in my charger. I was just trying to figure out what the item in the diagram is that I circled. I ordered a new relay but I didn't know what that was in the diagram as there currently is nothing where the relay should be.
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