1995 club car 48 volt - charging issue?

[Rocknd]

Hello and thanks for your assistance-
I have a 1995 Clubcar, 48 volt golf cart. The Batteries are 2 years old and my wife and I have been very attentive in making sure the cell fluid levels are maintained with distilled water. Each battery tests out above 9 volts and the entire pack charge tests out at 57.3 volts.
Within the last few months, I have noticed that the amp meter on the charger reaches around 4 amps, but seems to stay there without finishing the charge cycle and shutting itself off.
At first blush, the charger seems to be functioning as it should:

1. Comes on when plugged in.
2. Meter jumps to about 15-20 amps.
3. Meter returns to zero.
4. Meter jumps back to 15-20 amps and remains on.
5. Meter reading lowers as charge increases.
6. Seems to hang at 4 amps.

I have read in several posts that it could take up to 16 hours to fully charge. Could it be possible Im simply not letting charge long enough or does this sound like there may be other issues.
The reason Im asking this is Ive contacted a mobile cart repair person who charges $75.00 just to show up. When I spoke to him on the phone, the first thing he said is "I charge $1,000.00 for new batteries". Im wondering if this guy is just a battery peddler.
Thanks for the help

[golfcartg]

It sounds like your charger is doing most of what it should, but the fact that it hangs at 4 amps and doesn’t complete the charge cycle could be indicative of an issue with your Onboard Computer (OBC) if equipped (see attached photo). The OBC in most 48v Club Car's is responsible for regulating the charging process and managing the overall battery health. When the OBC starts to malfunction, which is common, it can lead to symptoms like the ones you're describing, where the charger doesn't seem to shut off properly or takes an unusually long time to complete a charge. The OBC might not be detecting when the batteries are fully charged, causing the charger to stay in the low amp charging mode indefinitely. This can also explain why your amp meter hangs at 4 amps and doesn't finish the cycle.

As for your batteries, from what you’ve described, they seem to be in good condition. Testing above 9 volts for each battery and having a total pack charge of 57.3 volts is a positive sign, especially since they’re only two years old and you’ve been diligent with maintaining the fluid levels. Given these readings, it’s unlikely that your batteries are the root of the issue.

Regarding the battery price, it does seem that the repair person you spoke with is quoting on the higher end. Battery costs can vary significantly based on the brand and type of battery. A high end set could indeed cost around $1,000, but there are more affordable options available. For example, a set of decent quality batteries from a place like Costco might run you under $700. Since your current batteries seem to be in good shape, you might not need to replace them, especially if you can confirm that the issue lies with the OBC or another part of the charging system.

If you do decide to investigate further, you could try resetting or replacing the OBC to see if that resolves the issue. This can sometimes correct charging problems and get things back on track. If resetting the OBC doesn’t help, you may want to consider having the batteries tested under load. Overall, your batteries seem fine based on the information you provided, so it may be worth exploring the OBC or charger further before considering a full battery replacement. If you have any questions feel free to ask!