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Unread 08-31-2013, 03:15 PM   #1
Gone Wild
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Default charger turns off after 5 minutes

I have a 2008 DS 48 volt.

Batteries were 2 years old, and dead. I was able to bypass the charger, and charge them with a stand alone charger. Once I got them charged up, I did a discharge test on the pack, and result was 7 minutes run time.

At that point, I installed all new 8 volt USBattery batteries. I plugged in owners charger, charger ran for 5 minutes and shut off. I did not drive cart. Let it sit for 2 days. Checked voltage, result is 47.2 volts.

I then hooked a different charger up, and this charger also ran for 5 minutes and shuts off.
When either charger is hooked up and charging ( during the 5 minutes), the output voltage at the pack is 49.3 volts, either charger.

If I unplug the dc cord, at no time does the amber lite ever come on. I checked gray wire fuse, and it is ok. Checked all connections, and charge receptacle, all good.

At this point, I am thinking the obc is bad, don't know what else would cause this. The new batteries are not getting charged in this 5 minutes, need to get these charged.

Advice??
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Unread 08-31-2013, 03:17 PM   #2
Dawg Gone Wild
 
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Default Re: charger turns off after 5 minutes

Have you put new battery cables on this car? If so, did you route the wire through the OBC?
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Unread 08-31-2013, 03:24 PM   #3
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Default Re: charger turns off after 5 minutes

no I did not change cables. All cables look great, and yes the negative does go thru the obc.
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Unread 08-31-2013, 03:25 PM   #4
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Default Re: charger turns off after 5 minutes

to by pass OCB
DO AT YOUR OWN RISK.…do not attempt unless you are familiar with electricity and electronics!
There are two ways to force the charger to turn on regardless of the OBC.

The first method is to disconnect the cart’s gray wire at the fuse near the charger receptacle. Then using a jumper wire, connect the receptacle side of the fused connector to the cart’s negative battery terminal. This will energize the charger’s 48V relay. If the charger doesn’t come on, it could be bad connections, wiring or charger relay.

The second method is to open the charger and remove the 120V wires from the relay and jump these together. This totally bypasses the relay and the OBC wire.


(If charger comes on but the charger ammeter shows 0 amps, check the fuse at the charging receptacle under the clear plastic cover.)

Both of these methods should both be temporary measures for troubleshooting, or as an emergency method of charging the batteries when they have been discharged so far that the OBC will not charge them.

The OBC provides the optimum method of charging the cart’s batteries. If the OBC is bad, it should be replaced
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Unread 08-31-2013, 03:29 PM   #5
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Default Re: charger turns off after 5 minutes

ctd

I
don't want to bypass, I want to fix whatever is wrong.

I have a charger that I can hook directly to batteries to charge, but this is not my cart. I am fixing it for someone else.
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Unread 08-31-2013, 03:57 PM   #6
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Default Re: charger turns off after 5 minutes

if you bypass OCB and it charges then the OBC is bad .. it an ez test
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Unread 09-01-2013, 03:38 PM   #7
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Default Re: charger turns off after 5 minutes

crash :

I tried your jumper from negative to the yellow fuse holder, and the charger came on and is staying on .

BEFORE I tried the jumper, the charger would come and charge for 5 minutes then shut off. DURING this 5 minute stretch I checked the pack voltage while charging, and it was 49 volts.

NOW , WITH THE JUMPER, charger stays on ( I know this is temporary fix), and the voltage during the charge is at 54 so far.

SO does it sound like I need a new OBC???
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Unread 09-01-2013, 04:13 PM   #8
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Default Re: charger turns off after 5 minutes

yes ... i think OBC does a self test and thats whats shutting it down
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Unread 09-01-2013, 05:00 PM   #9
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Default Re: charger turns off after 5 minutes

Thanks crash, you rock!
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Unread 09-01-2013, 05:44 PM   #10
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Default Re: charger turns off after 5 minutes

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