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Old 11-19-2014, 11:21 AM   #1
JLusk
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Default 36 volt EZ-GO won't charge

I'm stumped,working on a 2008 EZ-GO 36 volt, with new batteries producing 37.5 volts when tested. I have tried 5 different chargers on it and none will come on yet when I test the same chargers on other carts they all work fine. The charger plug is good,clean and snug,all wiring is like new and yields proper continuity when tested. Individual battery tests shows no problem. The original charger is a PowerWise QE however I have tried using the older PowerWise chargers that I know function properly and the results are the same. None of the chargers will come on.
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Old 11-19-2014, 11:27 AM   #2
rib33024
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Default Re: 36 volt EZ-GO won't charge

Welcome to BGW


Have you tested the volts at the plug on the cart body? where does your white and black wires coming out of the charge plug on the cart hook up to?
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Old 11-19-2014, 11:37 AM   #3
scottyb
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Default Re: 36 volt EZ-GO won't charge

Quote:
Originally Posted by JLusk View Post
I'm stumped,working on a 2008 EZ-GO 36 volt, with new batteries producing 37.5 volts when tested. I have tried 5 different chargers on it and none will come on yet when I test the same chargers on other carts they all work fine. The charger plug is good,clean and snug,all wiring is like new and yields proper continuity when tested. Individual battery tests shows no problem. The original charger is a PowerWise QE however I have tried using the older PowerWise chargers that I know function properly and the results are the same. None of the chargers will come on.
Ezgo charge receptacles are notorious for having worn out connector problems. These connectors are called Rad Soks. They are not cheap. Plug in a known good charger. Lift and hold the plugged in cord end to make good contact. Wait a minute - if the charger cones on replace the Soks shown here.
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File Type: jpg Ezgo Reed Switch bypass.jpg (169.2 KB, 0 views)
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Old 11-19-2014, 11:50 AM   #4
JohnnieB
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Default Re: 36 volt EZ-GO won't charge

As mentioned, check the voltage at the cart's charge receptacle. It ought to same as pack voltage.

If zero, the fuse in either the black or white wires that connect the receptacle to the battery pack, might be blown.

If pack voltage is present, clean the outside of the negative radsok. That is where the chargers sense the pack voltage.
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Old 11-19-2014, 12:16 PM   #5
JLusk
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Default Re: 36 volt EZ-GO won't charge

I have proper voltage at carts receptacle (37.5),I have also opened up a working charger and tested inside the charger while plugged into the cart. I get incoming voltage as it should be. I have also replaced the receptacle on the cart with another functioning unit just to 100% eliminate that area.
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Old 11-19-2014, 12:36 PM   #6
JohnnieB
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Default Re: 36 volt EZ-GO won't charge

Quote:
Originally Posted by JLusk View Post
I have proper voltage at carts receptacle (37.5),I have also opened up a working charger and tested inside the charger while plugged into the cart. I get incoming voltage as it should be. I have also replaced the receptacle on the cart with another functioning unit just to 100% eliminate that area.
When the charger IS NOT plugged into AC outlet, plug the charger into the cart.
Does the relay inside the charger click?
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Old 11-19-2014, 01:14 PM   #7
JLusk
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Default Re: 36 volt EZ-GO won't charge

I do not hear the relay click on any of the chargers when plugged into the cart.
The small red/white stripe wire going to the cart plug is attached to the positive (white) wire.
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Old 11-19-2014, 01:47 PM   #8
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Default Re: 36 volt EZ-GO won't charge

Quote:
Originally Posted by JLusk View Post
1. I do not hear the relay click on any of the chargers when plugged into the cart.

2. The small red/white stripe wire going to the cart plug is attached to the positive (white) wire.
1. If the relay in the charger does not click when charger is plugged into cart, the charger is not sensing the battery pack.

2. If you are speaking about the smaller of the three wire coming out of the back of the cart's charge receptacle, it is supposed to connect to the white (Positive) wire and it has nothing to do with the actual charging of the battery pack. (It is the output from the reed switch, which disables the cart when the charger plug is inserted into the charge receptacle. Other than that, it has no association with battery charging.)

The black and red wires on the control board inside the charger sense the pack voltage. The red wire from the control board attaches to the heatsink inside the charger, which is positive. The black (negative) wire attaches to the third wire in the charger's output cable, which in turn attaches to the Auxiliary contact (Item 36 on attached drawing) in the charger plug.

The Auxiliary contact is supposed to touch the outside of the negative radsok in the cart's charge receptacle and complete the battery sensing circuit.

------------
Taking into consideration that you have pack voltage present on the radsoks in the cart's charge receptacle and chargers that work on other carts, will not work on your cart, the obvious conclusion is that the Auxiliary contacts are not making contact with the negative radsok.

I suspect the outside of the negative radsok is tarnished.

---------
Added
Here is a schematic of a Powerwise charger with the battery sense circuit traced.
Attached Images
File Type: jpg Charger Plug - opened.JPG (40.8 KB, 0 views)
File Type: jpg PW Charger Schematic - Batt sense traced.JPG (47.8 KB, 0 views)

Last edited by JohnnieB; 11-19-2014 at 01:50 PM.. Reason: Added stuff
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Old 11-19-2014, 02:10 PM   #9
JLusk
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Default Re: 36 volt EZ-GO won't charge

I have replaced the cart charging receptacle with a working one-nothing,I have even 'jumped" around the receptacle to the charger plug and still nothing.
I appreciate all the time and effort y'all are giving.
Thanks
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Old 11-19-2014, 02:23 PM   #10
JohnnieB
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Default Re: 36 volt EZ-GO won't charge

Quote:
Originally Posted by JLusk View Post
I have replaced the cart charging receptacle with a working one-nothing,I have even 'jumped" around the receptacle to the charger plug and still nothing.
I appreciate all the time and effort y'all are giving.
Thanks
That points to a high resistance connection someplace in the charging loop.

I suspect you are using a DVM and having a high impedance input, they will measure voltage through connections that hardly exist.

Remove the black wire and the white wires from the battery pack (including the 50A or 60A fuse if it exists).
Measure the resistance of each wire from the front of the receptacle to the loose end.
It ought to be zero Ohms.
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