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Unread 06-10-2014, 11:02 AM   #1
Not Yet Wild
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Default 04 ds not charging

I recently purchase a 2004 club car ds from my grandpa. it is a 48volt cart 6 x 8volt. the problem I am having is getting it to charge. this cart has been sitting up for about a year. I have added distilled water to all the battery to cover the plates. all battery's are showing 3.10-3.30 volts. Do you think I could salvage these battery's? I have tried my charger on another cart and it works. I am just wanting to make sure the correct wire to jump the obc. there is a black wire with the larger fuse and a gray wire with a 3/8 amp small round glass fuse. Just trying to make sure I jump the correct wire.

thanks
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Unread 06-10-2014, 11:11 AM   #2
Epb
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Default Re: 04 ds not charging

The charger won't kick on with that low of voltage. You need to charge the batteries individually to get battery up to 8. There may be some leeway like 7.5 or something but not at 3v. I don't think you can salvage them but it's worth the try. I think anything is worth a try as long as it doesn't have the chance to hurt you.

To jump obc when and if needed is gray wire with 3/8 fuse connected to #6 neg with a jumper. Plus read the stickies for great info. welcome to the forum. Tons of great info and great people to help us out.
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Unread 06-10-2014, 11:19 AM   #3
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Default Re: 04 ds not charging

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.

Last edited by crash test dummy; 06-10-2014 at 11:21 AM.. Reason: added
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Unread 06-10-2014, 11:38 AM   #4
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Default Re: 04 ds not charging

Thanks for the info. I will try to jump the obc this week and see if I can get the battery's to hold a charge. Great Forum with a lot of Great info. I have definitely learned a lot in the past few days reading on here.
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Unread 06-10-2014, 12:05 PM   #5
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Default Re: 04 ds not charging

Hey guys, if the charger relay is not coming on because of low battery voltage, that jumper will not make it work.

Also, if the batteries are that low, the charger will run at a very high current, possibly damaging the internal SCR in the OBC that controls the charging current.

It would be better to:
1) Run a 10ga cable from the negative side of the charger receptacle directly to the pack negative.
2) Remove the fuse from the gray sense wire.
2) By-pass the charger relay inside the charger.

The breaker in the charger may pop a few times until the batteries get enough charge.

Keep an eye on the pack voltage since the charger will never turn off with the bypass in place.

Turn off the charger once you get to about 50v.
Remove all jumpers from the charger and cart, re-install fuse.
Reset the OBC.

Plug charger back on and let it run a normal charger cycle.

Good luck.

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Unread 06-10-2014, 12:21 PM   #6
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Default Re: 04 ds not charging

Quote:
Originally Posted by Sergio View Post
Hey guys, if the charger relay is not coming on because of low battery voltage, that jumper will not make it work.
it has worked for me quite a few times as i live in a park where the old people leave their carts uncharged for 6 months ...
yes i use it to get batteries up to a voltage where charger comes on ...and i do a OBC reset
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Unread 06-10-2014, 12:28 PM   #7
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Default Re: 04 ds not charging

Crash, I think you are correct when the voltage is too low to activate the OBC, but high enough to engage the relay. A 48v relay needs about 36 volts to turn on, the OP battery voltage numbers are way too low for that.
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Unread 06-10-2014, 12:33 PM   #8
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Default Re: 04 ds not charging

Would it be better if hook up a 24volt charger and charge three batteries at a time until I get the voltage to were I need it to be?
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Unread 06-10-2014, 12:34 PM   #9
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Default Re: 04 ds not charging

Quote:
Originally Posted by Mcurry1215 View Post
Would it be better if hook up a 24volt charger and charge three batteries at a time until I get the voltage to were I need it to be?
If you have access to a 24 volt charger, then yes.
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Unread 06-10-2014, 12:37 PM   #10
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Default Re: 04 ds not charging

Quote:
Originally Posted by 93yellowclubcar View Post
If you have access to a 24 volt charger, then yes.
x2 (...although a 24v charger may not turn on either due to low battery voltage)
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