2008 RXV wont run with neg charger hooked up

jeremykent

I had a call on a 20008 rxv. The customer installed 2 new batteries and the cart would not run after that. I checked all the wiring and all is good. After messing around I found where they extended the black ground wire coming out of the gray casing at the charger port to reach the back battery to 48 volts. The old piece of wire thy cut off was only long enough to reach the front battery for 12 volts. Thinking this had something to do with it I removed it. In the process I had to pull the charging ground (heavy black) from the battery when I did that it started beeping (because it was in reverse). I put the wires back on except the 2 grounds coming from the charger port and the cart worked. It continued working regardless of where I hooked up the ground in the gray casing either 12 or 48 volts. However when I hooked up the heavy ground from the charger port the cart would not do anything. And the charger also goes into fault when you try to charge. I dont know much about these AC carts so any help would be a big help.

BGW

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cgtech

The grey casing has 2 wires in it and isnt a "ground" or to be connected to a "ground". They go to a temp sensor, (that little black box with a ring terminal sticking out), the ring terminal does not send any power (from any battery position) to the charge port, only that terminal temp. The charge port can disable the cart when it thinks a charger is plugged in (thats likely whats currently shutting you down). A new temp sensor alone can be had from fullriver battery, or a whole new charge port from ezgo. Sounds like its gonna be a new charge port. Its unadvisable to start cutting & extending wires that you do not understand, it gets costly.

jeremykent

OK I get the wires in the gray are for temp. Currently the cart has the red to the same positive post that feeds the controller, the black is also on the neg lead that goes to the controller. This is what they did when they changed batteries. Should they both go to an individual battery or does it matter? I will check on the charger port as well.

jeremykent

Actually now that I looked at a new charger port I can see there are 3 pins on the cart side. I am pretty sure the cart does not have 3 on it now and the neg side of the temp wire does not have the box on it. Is it possible the cart worked and charged in the past without that post? It is possible when somebody was messing around extending the wire they may have done more and not told me?

cgtech

From the charge port- largest black wire goes to the back battery post nearest controller (lets call it "Pack main -"), largest red wire goes to positive terminal on front battery nearest the controller (lets call it "Pack main +"). The grey "wire" (which is 2 wires to temp sensor) is normally attached to "pack main +" but must have the temp sensor (dont hook them to the batterys without it). I think you, or someone, may have destroyed the charge port with mis-wiring. The small wires in the grey "wire" dont touch any of the batteries with an "electrical connection". I'll see if i can whip up a crude drawing....

cgtech

Heres the crude drawing of the original configuration. The black "blob" at the end of the of the grey "wire" is the temp sensor. I repeat, neither of those two tiny wires are supposed to make contact with the battery terminal, they connect to the temp sensor that reads the battery terminal temperature. The 4th blue wire from the charge port is the wire to the controller to disable the cart when the charger is plugged in, it has zero volts when the charger is plugged in, and has 48v + when the charger is not plugged in. Drawing is crappy, i just drew it on my 3 year old phone....

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jeremykent

Gotcha. I dont know how long the cart had the red/black separated from the box (temp sensor) or how it was wired before i got there????? Anyhow I will order a new charger port and get that part right that will hopefully solve the issue or at least I know that will be right and can move on. Thank you for your help!