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Old 08-13-2018, 04:10 PM   #1
december45
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Default Club car 48 volt won't charge

It is a 1995 club car cart;
A 9528-445415

The charger is a;
Power Drive
17930
Domestic
4/1995

The problem;
When I plug it in the charger it clicks,(and hums) like its going to charge but the needle stays all the way to the left, (usually it will move to mid way or further to the right)

My thoughts, and checks;
I am at first thinking OBC but that is just a guess on my part.
All batteries are new, and have good clean positive connections, the charge connections seems to have good connections no loose wires that I can see or feel. The plug connection to the cart is tight and secure not loose or sloppy.

Are there any other symptoms to look for regarding the possible bad OBC or am I barking up the wrong tree?
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Old 08-13-2018, 09:59 PM   #2
NoleFan4Ever
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Default Re: Club car 48 volt won't charge

Check the main fuse on the back of the charge receptacle. If it blows, it will not pass current and will just sit there and hum.... It is #6.

DS_Charger_Receptacle.jpg
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Old 08-14-2018, 08:26 AM   #3
Fairtax4me
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Default Re: Club car 48 volt won't charge

OBC is fine. It tells the charger relay to turn on, but doesn't have anything to do with how much amperage it delivers.

Like Nole said, check the fuse on the back of the charge receptacle. Also the old PD charger should have a fuse on the front of the charger.
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Old 08-14-2018, 08:30 AM   #4
december45
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Default Re: Club car 48 volt won't charge

I am going out this morning to check it out.
If the fuse on the charger is blown/no good would it even turn on? Or would it turn on and not charge?
And how does that fuse on the charger come out to check if its good?
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Old 08-14-2018, 09:36 AM   #5
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Default Re: Club car 48 volt won't charge

The big fuse on the front of the charger is on the DC side, so if it blows the charger will still hum, but wont have any output. Easy to see, and there wont be any question if it's good/bad.
It's only replaceable from inside the charger. Pretty easy to do with some basic tools. The only reason I've ever seen one fail was because the DC charge cord was damaged.
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Old 08-14-2018, 10:08 AM   #6
december45
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Default Re: Club car 48 volt won't charge

Checked the fuses on the cart, charging plug receptacle and the charger all good
Ran the ground wire from the battery pack - to the charging receptacle.
The charger started charging as it should....
It is charging with full amps the needle is pegged to the right charging.
Now my questions;
Can I be pretty certain that the OBC is bad?
What exactly have I done by sending the ground directly to the charge receptacle?
Can I continue using my Power Drive charger?
and should I think about replacing that OBC, where is the best place to buy one?
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Old 08-14-2018, 12:36 PM   #7
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Default Re: Club car 48 volt won't charge

You have proved the OBC to have partially failed because it came on with out moving the grey sense wire over the the Main Neg.

You are fine to "temporarilly" use it this way, but you can not leave it without monitoring it. You are only surface charging the batteries as there is no algorithm or any controls for it so once it get to ~61vdc or so, you will have to unplug it.

You can get you a new OBC here https://www.revolutiongolfcars.com/p...-ds-series-48v or if you prefer to do a permanent bypass and remove the OBC, then purchase a new smart charger. Up to you....
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Old 08-14-2018, 02:59 PM   #8
december45
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Default Re: Club car 48 volt won't charge

I disconnected the battery cables and left it for a hour, in hopes of resetting the OBC and it seems to have worked.
disconnected the ground wire that by passes the obc and plugged in the charger, its charging
I am guessing its working at least for now
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Old 08-14-2018, 03:06 PM   #9
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Default Re: Club car 48 volt won't charge

Sounds good.....
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Old 08-14-2018, 03:11 PM   #10
december45
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Default Re: Club car 48 volt won't charge

thanks for your help i appreciate it, you guys saved me
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