1996 club car battery indicator flashing

I still suspect something in the OBC (black box magic!). I cant see how the relay can cause such a big voltage drop, but what ever is causing this voltage drop is the reason that the charger relay does not kick in. I tested the charger relay separately to see what the current draw on the relay is and found that only a few milli amps are required to energise and hold the relay in. I was able to test this voltage (gray wire pin to battery positive) with the charger plug out (Battery Voltage) but when I plug the charger in it drops to about 2 Volts. My understanding is that if this voltage is above a certain value (whatever the pickup voltage of the charger relay is) it will turn the DC relay in the charger ON, which in turn turns the transformer and rectifier side of the charger on. The other test that I did was using my multi-meter I tested the gray wire to cart positive (pins in charging receptacle) and measured almost battery voltage. Yellow fuse (gray wire)and the fuse on the charging receptacle are OK.

I am reluctant to purchase a new OBC before I fully understand how the system works.Īny comments or advise will be much appreciated This is also a calculated value I assume, calculated by the OBC? The battery light on my cart does not turn on at all, I have simulated low voltage on the system using a variable DC power supply connected to the carts main + and - terminals (with the batteries removed from the cart) raging from 25 V to 51 Volts and nothing, another indication to me that OBC has failed. I am also trying to understand the function / operation of the battery indicating light on the dash, my understanding is that it is also controlled by the magical OBC, turning on when the battery charge level gets below a certain point. Is there any other test that one can do on the OBC to prove that it is working or failed? (I understand that it is a sealed box with no access to the components in side) By bypassing the OBC I can get the charger to kick in and the current seemed to be falling in the short time that I had the bridge in place, (the batteries are holding their charge quite well, around 8.5 Volts, so I expected some current during the test, I did not leave the charger on as all I wanted to do was hear the magical 'click' of the DC relay indicting that the charger is working ). I have concerns that the OBC has an issue and I have even tried the reset procedure to try and get something happening but no luck. The big issue that I have is that the batteries will not charge using the original charger plugged into the cart receptacle. I was able to nurse some life back into all of them (using a different charger that I borrowed) enough to test the cart and it actually drives fine. When I first got the cart home the batteries were pretty flat and not in a good condition. I am working on restoring a 97 Club Car DS Powerdive which has many issues. New to the forum so apologies if these questions sounds silly.

1996 club car battery indicator flashing