'97 48V Battery light on intermittent & won't charge intermittent

[Michrider]

Hello all, on my '97 48V I'm having a problem with the red battery warning light coming on intermittently. When the light is on the charger will not start charging. If I let it sit for a while, the light will go off and it will charge just fine if I plug the charger in when the light is off.

Batteries are 1 year old and in excellent shape. All over 8V and in series 50 to 52 volts. Cart operates great. Charger works perfect on other carts.

Another strange thing is the state of charge indicator always reads fully charged.

I've checked connections everywhere, can't find anything simple. Am thinking it is one of the modules, something solid state going haywire in the charging circuit.

Any ideas on what to check. Thanks a lot.

[dcannow]

Had the same thing on a 96CC. Solved the problem by just disconnecting the sucker!! This must be a common problem as others have complained as well.

[GLEEMO]

The Next time this happens, take a pack reading and post the results here ,
Sounds like old cables or a Battery problem.

[Michrider]

Batteries and cables all look real good. I changed the batteries last year with new 8Vs. Voltage reads 52V +, and all batteries read well over 8V. Cables are all clean and tight, no corrosion - I keep dielectric grease on all the cable ends.

To me it seems like something solid state is triggering the light to come on by the way it is pretty consistent.

When the charging is done. I'll pull the charger cord out and about 10 seconds later the red battery light will come on. Then after a little while it may go off. It will charge fine if I start the charge with the light off. But if the light is on, the charger will not start.

At one time it seemed like the light was coming on when I wiggled the grey wire in the middle of the charge recepticle. But that may have just be coincidental timing.

I'll try disconnecting the battery circuit, not sure if that will reset some type of memory. I've also seen to run the batteries down low, and then recharge.

Any way to know for sure if it is the OBC? If it is, any suggestions on cheapest place to buy one online?

[GLEEMO]

Have you tried resetting the OBC ;
Let us know if this helps with your problem
Resetting the OBC
To reset the OBC the following must be done in this
order:
If no Tow/Run Switch then skip that step

• Key Switch to Off
• Forward/Reverse to Neutral
• Tow/Run Switch to Tow
• Disconnect the Battery NEGATIVE (–) wire
from the Battery Minus terminal on the battery
pack.
• Put the Tow/Run to Run
• Forward/Reverse Switch to Reverse
• Key Switch to On
• Lock the throttle pedal down
The reverse buzzer will sound and go off in about 30
seconds. Leave the cart like that for 5 min to cause the
OBC to reset.
To reconnect the OBC back into the system:
• Key Switch to Off
• Forward/Reverse Switch to Neutral
• Tow/Run switch to Tow
• Reconnect the Batt – wire to the battery minus
terminal on the battery pack.
Once the OBC has been reset, the cart can be
troubleshot. There is always a chance the OBC has
completely failed and the reset process will not fix the
problem. Consult your Club Car manuals or contact
Alltrax for more troubleshooting of vehicles with an
OBC.

[Michrider]

Thanks, I'll give that a try. I don't think it has a tow run switch. Have not seen anything like that. Would that be on the dash or under the seat if I did have a tow/run?

[GLEEMO]

No it is under the seat , you would know if you had one BIG Yellow !!
I have a 99 ,no run/tow switch

Dee Pics here http://www.buggiesgonewild.com/elect...en-system.html

[miferrel]

To BGW

[GLEEMO]

The OBC and Power Drive chargers work together.

If the OBC sends a signal back to the charger that the 48 Volt pack has less than 36 Volts
then the charger will not turn on. (it thinks the user should be warned there is a Major problem).

So the next time it happens , check Pack Voltage while it is not working (charger will not come on and light is on).
If the voltage is normal then it is probably your OBC !

If it is not normal you have a intermittent cable in the pack or to the OBC.

[Michrider]

Hey again.

I'm still having this problem with this cart. Battery light will intermittently come on, and when it's on - the charger will not start.

Batteries and cables are perfect. 55.6 volts showing on the pack after a charge. Batteries are 1 year old, cables are all clean and tight.

Last time I got it to charge, it charged the full charge cycle, I unplugged the charger, and as soon as I pulled the charger plug out of the cart - the battery light came on. A couple hours later, it went off.

If the light is on, I can sometimes just turn the key on - go in reverse and forward a few feet and the light will go off. Push the charger plug into the receptical, and the light will come back on. I'll just have to try again the next day and sometimes the light will stay off and the charger will kick on.

Another odd thing - the battery state of charge meter alway reads full. Even after a couple hours of use and batteries drained way down.

Should the batteries be boiling toward the end of the charge? Last charge up, right toward the end when the charger was showing about 2 amps - I could hear the batteries boiling quite a bit. Is that normal?

Anyone have a service manual that shows what to check when the battery light is on? I'd hate to buy a new OBC and still have the same problem. I'm good with electrical/wiring repairs, but don't have a manual for this cart.

One more question. Is the OBC the module on the passenger side? Or is it the thing on the drivers side with the battery cable running through the hole? I take it that things is measuring amp draw. Any diagnostic tips on how to tell which one is causing the problem?

I tried the OBC reset procedure several times - no change.

Many thanks!