Charger/sense lead fuse issue

[Shandog777]

I am working on a 2003 clubcar DS that the charger will not kick on when plugged in. I tried three separate chargers. Nothing.

The sense lead fuse has broken. Could this be the problem with the charger not kicking on?

The batteries are only a year old and they are great. When we plug in the charger nothing happens. I was looking at OBC but noticed the fuse broken. I am hoping this is it.

[movin-on]

That is your problem...You have to replace it with a 3/8 amp glass fuse only, nothing else..Get it from Dave at Revolution or Google search for it..That gray fused wire supplies the negative signal from the obc to the charger relay to turn on the charger...You can temporarily get the charger to turn on to charge the cart by jumping the receptacle end of the gray wire where the fuse goes to pack negative...

[Shandog777]

Okay I replaced the fuse and noticed that the gray line wasn’t very secure in the receptacle. I cleaned the end of it off and reinserted it back in the receptacle and it is charging now!

If I barely bump the gray line it shuts off the charger. After just a moment it turns back on. . Is this normal?

If not what is my next plan of action?

[kgsc]

I’m not as knowledgable in the club car world but those are known for failure from corrosion. Need to replace the receptacle.

[movin-on]

Normally you have to replace the receptacle...I have taken them apart and soldered the end of the gray wire onto the sense pin...You have to get the pin pretty hot but it can be done...A mini torch comes in handy for the job...