96 DS On Board Computer

[Handz37]

New to golf carts, just purchased a fixer upper. Looking for some knowledge on the charging circuit within the OBC. I recently purchased a 48v 96 DS electric cart with weak-fair batteries at best. I knew that going into it. I also knew that they had mickey-moused the charging circuit because they were using an outlet timer to turn the charger off after a pre determined amount of time. Once I got the cart in my possession, I charged it for about 14 hours, got the batteries up to about 52 v, let sit for about 4 hours and checked the cells for specific gravity. They tested in the fair range on average, and after sitting for almost 12 hours I am holding steady at 49 volts. I will probably replace the batteries after I get the charger figured out. I figure there is no point in installing new batteries until I know that automatic charger is working correctly.
WHAT I FOUND: Someone had wired around the relay in the charger to make charge constant. Bench tested relay and it tested good. So i wired it back up as it shows in schematic. Found that someone had ran a jumper wire from the fusible link on charger receptacle on cart to the ground of the battery, I removed that from cart trying to get back to OEM. I checked the the fuse on the sense line, it is fine. I checked continuity through the DC charge connector, all 3 connections are good through there. I checked the fuse on the red wire going to the OBC, it is good. I think I might need to replace the OBC, but not positive. Also, I have read that while the cart is plugged into the charger, it should not move forward or reverse, mine does. My cart has no problems driving (once batteries were charged), I just can't get charger to come on automatically. Any foresight into this matter would be very appreciated. Also, as I believe that I will be replacing the OBC, I started removing it. Can someone tell me the easiest way that is done, how do I get the large ground wire out of it, or does it come with a new one??? Also how does it unplug, or does it also come with a new harness? Thank you everyone.

[mrgolf]

Forget the OBC and get a DPI charger from scottyb, site sponsor. Cost close to what an OBC would cost and is a lot better for your batteries.

[scottyb]

Even Club Car eliminated the OBC in later year carts after a blundering 10 year experiment. It was probably one of the worse golf cart engineering ideas ever implemented. Basically took a simple circuit board and tripled the cost by incorporating it into a cart debilitating OBC. You have 3 options.
You can replace it.
You can get an aftermarket control circuit board for your charger.
You can get a stand alone charger.

[Handz37]

Thank you guys.