:mrgreen::mrgreen:(please read entire article before beating the OBC) We have a 98'ish club car DS where I work. Last week the battery light started flashing and it quickly began losing power. We were able to push it into the shop but until yesterday I did not have time to address the problem.
I started reading threads and was able to get the light to stop flashing by disconnecting the battery bank for about 15 minutes. The charger would not kick in while the light was flashing nor would it kick in after I got the light to stop flashing (when the light stopped flashing the battery indicator showed a full charge).
I topped off the battery water, took off and cleaned the battery connections, checked individual voltage 7.4v across the board (connected in a series around 46v). I tried bypassing the OBC by breaking the connection at the yellow fuse holder (receptacle side) keeping the fuse in position and jumping from the fuse to the negative side of the number six battery as posted in other threads. The charger did not kick in.
I then bypassed the relay inside the charger with a nifty jumper made out of two male spade connecters. Viola it works. I know it is now a manual charger. My long story short question that I believe I already know the answer to but would like to verify with the experts here is this. Is it the relay? That might sound silly, I just want to verify the testing methods were correct before I buy a relay that isn't bad. Any other tests needed to verify it is not the OBC or the funky little circuit board in the charger?
I don't want to toot my own horn but I know my way around mechanics. There are two things I don't do well with, circuit boards and little magic black boxes that wires go into and come out of but ya don't know what's inside cause it's all glued up like now one wants you to look at!!!!
I started reading threads and was able to get the light to stop flashing by disconnecting the battery bank for about 15 minutes. The charger would not kick in while the light was flashing nor would it kick in after I got the light to stop flashing (when the light stopped flashing the battery indicator showed a full charge).
I topped off the battery water, took off and cleaned the battery connections, checked individual voltage 7.4v across the board (connected in a series around 46v). I tried bypassing the OBC by breaking the connection at the yellow fuse holder (receptacle side) keeping the fuse in position and jumping from the fuse to the negative side of the number six battery as posted in other threads. The charger did not kick in.
I then bypassed the relay inside the charger with a nifty jumper made out of two male spade connecters. Viola it works. I know it is now a manual charger. My long story short question that I believe I already know the answer to but would like to verify with the experts here is this. Is it the relay? That might sound silly, I just want to verify the testing methods were correct before I buy a relay that isn't bad. Any other tests needed to verify it is not the OBC or the funky little circuit board in the charger?
I don't want to toot my own horn but I know my way around mechanics. There are two things I don't do well with, circuit boards and little magic black boxes that wires go into and come out of but ya don't know what's inside cause it's all glued up like now one wants you to look at!!!!