Club Car DS "going to sleep"

[C2GCPVA]

We just finished up with this fun renovation of a 1998 Club Car DS 48V, and cant pinpoint why the cart keeps going to sleep. Renovation included new batteries, wires, remanufacturing the controller, New V Glide, Solenoids, and the rest was cosmetic.

The Cart always does this after disconnecting batteries, having to wake it up with the charger. The Charger doesn't even have to be plugged in, Just the unpowered DC Cord plugged in and the cart clicks awake. The issue is it keeps doing this sometimes after sitting overnight, sometimes after sitting for an hour. Holding the Accelerator pedal down wont wake up the cart, only plugging in the DC Cord.

Ran the OBC Reset Procedure, and the problem still comes up. Originally the cart would go to sleep and have to be woken up by plugging in the charger after it has sat overnight or over the weekend.

Went ahead and replaced the OBC with a used one we had around the shop and still having the issue.

Yesterday the cart ran fine and then an hour later went to drive it, and.....Asleep again.

We can force it to present this problem by disconnecting the batteries and are running through test procedures in the service manual and with the controller troubleshooting.

I have read through this thread - Concerning a Precedent acting similarly : https://buggiesgonewild.com/showthre...ighlight=sleep

Contemplating if we need to bypass the lockout side of the OBC or if anyone has any ideas/pointers specific to this model.

[Fairtax4me]

Is it a Regen or series cart?
If it's regen what controller do you have?

[C2GCPVA]

Originally Posted by Fairtax4me

Is it a Regen or series cart?
If it's regen what controller do you have?

It Is a Regen Cart with the GE Controller: GE 48V 220/20A Plug SX Controller, Part # IC3645SH4D222C1

[C2GCPVA]

As seen in a previous thread, we cut and connected the white and the blue wire that are on the back of the OBC. - Cart is not even going to sleep when you disconnect the battery wires now.

This appears to have been where the problem was! After hours of testing the controller pins, V Glide, charger receptacle... we should have tried this from the start!

Monitoring Charge Cycle now to make sure it doesn't affect controlling the charger.

Does anyone have further input/explanation on how we have affected the OBC Functions by connecting these two wires?

[C2GCPVA]

This is what we went off of : "Try unplugging the OBC 6-pin connector and jump the white and blue wires on the harness side (not the obc side) of the connector with a paper clip..That will bypass the lockout side of the obc..If that works you can make the connection permanent by cutting and joining those 2 wires together and plugging the connector back in so that the cart will still charge normally..."

Link to where we found this: https://buggiesgonewild.com/showthre...ighlight=sleep

[Fairtax4me]

It’s likely a failure in the controller. The Regen 2 OBC has a couple of wires that only go from the OBC to the controller and they are for the OBC wake-up function. When the throttle is pressed the controller sends voltage to the OBC which then provides power to the solenoids so the cart can operate.
If the OBC is not getting a throttle applied signal from the controller, the cart will not operate.
Repairing that would either mean fixing a wiring issue if there is damage to the signal wires, or to the controller 24 pin connector.
Or replacing the controller.

What you’ve done is bypass the lockout portion of the OBC which is totally fine, that’s the most common fix used when an OBC fails or when it is being replaced with a smart charger. You will not have a functioning charger lockout to prevent the cart from operating with the charger plugged in, so just be aware that the cart can still drive even if the charger is plugged in and charging.

[C2GCPVA]

Originally Posted by Fairtax4me

It’s likely a failure in the controller. The Regen 2 OBC has a couple of wires that only go from the OBC to the controller and they are for the OBC wake-up function. When the throttle is pressed the controller sends voltage to the OBC which then provides power to the solenoids so the cart can operate.
If the OBC is not getting a throttle applied signal from the controller, the cart will not operate.
Repairing that would either mean fixing a wiring issue if there is damage to the signal wires, or to the controller 24 pin connector.
Or replacing the controller.

What you’ve done is bypass the lockout portion of the OBC which is totally fine, that’s the most common fix used when an OBC fails or when it is being replaced with a smart charger. You will not have a functioning charger lockout to prevent the cart from operating with the charger plugged in, so just be aware that the cart can still drive even if the charger is plugged in and charging.

Appreciate the detailed explanation there on what we have done. Will be aware while charging that the cart can still operate.

Voltage is being sent to the OBC, So there must be a fault within the controller. Controller was just remanufactured and other faults corrected but they must have overlooked this one.

[mtollin]

Just remove the key when charging, and you won't have any accidents. You could even get a quick release key ring and attach it to charger cord when charging as a reminder.