2004 club car DS 48 v charging problem

Airpirate · 10-01-2018, 03:57 PM

I have a club car DS that has been functioning well. I replaced the old batteries and have gone through a dozen charge cycles and it runs well. The pack measures 49.1 volts but now the charger doesn't seem to work correctly.
When I plug it in the charger clicks and the charger meter deflects slightly negative and then nothing. I've tried another functioning charger of my friends with the same result.
I checked the battery connections, the two fuses at the charge plug location and all are good.
The wires leading from the charge plug to the batteries are clean and tight.
I reset the OBC and cleaned the charger plug and same result.
Plug it in, charger clicks and the meter either selects slightly negative or half and amp positive and falls to zero with no further action.

NoleFan4Ever · 10-01-2018, 04:01 PM

That would be your OBC.

You can bypass the OBC by running a jumper from the back side of the charge receptacle (where the black 10g wire is that goes into the harness) and run it directly to the Main Pack Negative. Also take the grey sense wire coming off the same receptacle and land it to the same place. This will allow the charger to turn on "if" the OBC has failed. Note- This is only to test and not to make normal operation. You would not be "charging" the batteries at all, just quickly surface charging the battery plates.

mrgolf · 10-01-2018, 04:15 PM

Does your battery pack negative cable still go through the hole in the obc?

TahoeDawgZ71 · 10-01-2018, 05:02 PM

Following... waiting on a response to NoleFan's post..... This will determine your answer.

Airpirate · 10-01-2018, 05:34 PM

There is the normal wire going through the OBC. Haven't tried bypassing however. May swap in a spare OBC and see if that fixes the problem.

NoleFan4Ever · 10-01-2018, 10:44 PM

Before I pulled it and recabled everything, I would first bypass it and verify that is it and not a Gremlin....

Airpirate · 10-02-2018, 07:22 AM

Good suggestion, I will do that. I have a rear seat I'd have to remove to get access to the OBC to change it out.

Airpirate · 10-03-2018, 05:10 PM

NoleFan4Ever
When I bypass do I need to remove the black wire from the back fuse connection on the receptacle and then run a new wire to the negative pack connection? Do I need to remove any existing wiring while I'm doing the bypas?
I was thinking of removing the existing heavy black wire and letting it hang loose and connecting a new jumper to the negative. Also was going to use a test lead with alligator clips to grab the end of the fuse and running that to the negative.

NoleFan4Ever · 10-03-2018, 06:06 PM

Both of those ideas will work. The grey wire is so the Charger can sense the charge and the Black is so it can complete the charge circuit.

Airpirate · 10-03-2018, 06:14 PM

Thank you sir.

10-01-2018, 03:57 PM	#1
Airpirate Not Yet Wild Join Date: May 2012 Posts: 60	2004 club car DS 48 v charging problem I have a club car DS that has been functioning well. I replaced the old batteries and have gone through a dozen charge cycles and it runs well. The pack measures 49.1 volts but now the charger doesn't seem to work correctly. When I plug it in the charger clicks and the charger meter deflects slightly negative and then nothing. I've tried another functioning charger of my friends with the same result. I checked the battery connections, the two fuses at the charge plug location and all are good. The wires leading from the charge plug to the batteries are clean and tight. I reset the OBC and cleaned the charger plug and same result. Plug it in, charger clicks and the meter either selects slightly negative or half and amp positive and falls to zero with no further action.
Airpirate Not Yet Wild Join Date: May 2012 Posts: 60

10-01-2018, 04:01 PM	#2
NoleFan4Ever MOD of all BS! Join Date: Sep 2011 Location: Florida Posts: 17,477	Re: 2004 club car DS 48 v charging problem That would be your OBC. You can bypass the OBC by running a jumper from the back side of the charge receptacle (where the black 10g wire is that goes into the harness) and run it directly to the Main Pack Negative. Also take the grey sense wire coming off the same receptacle and land it to the same place. This will allow the charger to turn on "if" the OBC has failed. Note- This is only to test and not to make normal operation. You would not be "charging" the batteries at all, just quickly surface charging the battery plates.

10-01-2018, 04:15 PM	#3
mrgolf Old Sky Soldier Join Date: Dec 2011 Location: Kentucky Posts: 3,881	Re: 2004 club car DS 48 v charging problem Does your battery pack negative cable still go through the hole in the obc?

10-01-2018, 05:02 PM	#4
TahoeDawgZ71 revolutiongolfcars.com Join Date: Mar 2010 Location: Golf Car Capital of The World... Augusta, Georgia Posts: 10,224	Re: 2004 club car DS 48 v charging problem Following... waiting on a response to NoleFan's post..... This will determine your answer.

10-01-2018, 05:34 PM	#5
Airpirate Not Yet Wild Join Date: May 2012 Posts: 60	Re: 2004 club car DS 48 v charging problem There is the normal wire going through the OBC. Haven't tried bypassing however. May swap in a spare OBC and see if that fixes the problem.
Airpirate Not Yet Wild Join Date: May 2012 Posts: 60

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10-01-2018, 10:44 PM	#6
NoleFan4Ever MOD of all BS! Join Date: Sep 2011 Location: Florida Posts: 17,477	Re: 2004 club car DS 48 v charging problem Before I pulled it and recabled everything, I would first bypass it and verify that is it and not a Gremlin....

10-02-2018, 07:22 AM	#7
Airpirate Not Yet Wild Join Date: May 2012 Posts: 60	Re: 2004 club car DS 48 v charging problem Good suggestion, I will do that. I have a rear seat I'd have to remove to get access to the OBC to change it out.
Airpirate Not Yet Wild Join Date: May 2012 Posts: 60

10-03-2018, 05:10 PM	#8
Airpirate Not Yet Wild Join Date: May 2012 Posts: 60	Re: 2004 club car DS 48 v charging problem NoleFan4Ever When I bypass do I need to remove the black wire from the back fuse connection on the receptacle and then run a new wire to the negative pack connection? Do I need to remove any existing wiring while I'm doing the bypas? I was thinking of removing the existing heavy black wire and letting it hang loose and connecting a new jumper to the negative. Also was going to use a test lead with alligator clips to grab the end of the fuse and running that to the negative.
Airpirate Not Yet Wild Join Date: May 2012 Posts: 60

10-03-2018, 06:06 PM	#9
NoleFan4Ever MOD of all BS! Join Date: Sep 2011 Location: Florida Posts: 17,477	Re: 2004 club car DS 48 v charging problem Both of those ideas will work. The grey wire is so the Charger can sense the charge and the Black is so it can complete the charge circuit.

10-03-2018, 06:14 PM	#10
Airpirate Not Yet Wild Join Date: May 2012 Posts: 60	Re: 2004 club car DS 48 v charging problem Thank you sir.
Airpirate Not Yet Wild Join Date: May 2012 Posts: 60

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