2002 EZGO will not charge

flynhigherx · 08-02-2011, 05:13 PM

I have read a lot of threads on the forum and can not resolve my issue without a little more expertise. I am sure the answers are here on the forum but I can not find them.

Cart has 37.4 VDC cart side on the receptacle. 5 batteries are 6.2 VDC and 1 battery is 6.3.

Charger is a PowerWise charger. The receptacle plug appears to be in good condition, for whatever that is worth. The charger doesnt do anything, not a sound not even a hum! The wall outlet appears to be functioning fine, it will run my pancake air compressor just fine.

From a previous thread I believe that I have a PDS cart.

What should I do next to troubleshoot my charging issue?

Thanks in advance for your help!

scottyb · 08-02-2011, 05:35 PM

I assume you checked the fuse inside the charger?
I assume the relay is not clicking when you plug it into the cart, even if you lift and hold on the plug for 15 seconds?

Is the 36v positive coming out of the charge receptacle on the cart side on the small red wire?

rabbitreborn · 08-02-2011, 08:24 PM

After you verify the 50 AMP fuse inside the charger is still good......

Unplug the AC cord from the wall, pull the 2 black wires from the relay inside the charger and connecct them together.

Plug the charger back into the wall and into the cart. Does the needle come up showing a charge?

flynhigherx · 08-02-2011, 09:19 PM

ScottyB,

Fuse inside the charger? I took the lid off actually looking for a fuse. I do not see one! I am looking for a glass type fuse. I see two other things that I believe could be fuses.

Nothing clicks! Even when I hold the plug up for 15 seconds.

Is the relay in the charger, receptacle itself or the controller box?

Small red wire voltage - (-)15.7 VDC If I understand what I am supposed to measure and how I am supposed to measure it. I also measured the voltage on the other side of the cart toward the controller, same reading. It looks like it heads toward the ignition switch after that?

flynhigherx · 08-02-2011, 09:27 PM

Rabbitreborn,

How do I verify the 50 amp fuse inside the charger?

I will bypass the relay and give it a try in the morning. My first reaction was to LMAO when you began with "first unplug the AC" however, I am more comfortable inside my 200 amp panel than inside the charger. With the charger unplugged is the capacitor the only thing that can tag me?

flynhigherx · 08-02-2011, 09:29 PM

Thanks guys for your really quick responses. I really appreciate your help fixing my cart!

rabbitreborn · 08-02-2011, 09:43 PM

Believe it or not, I have never been tagged by the Capacitor (and I take risks while handling them all the time). The esiest way to verify the 50 amp fuse it to do a continuity check through it (It should be in line between the white wire and the back of the Anmeter). Basically you have a red (14 guage connectes to the black that runs to the PC board inside the charger), White and Black coming from the charger cord. you should see pack voltage across the black and white, Also, you should see pack voltage across the White and red (you can disconnect it from the black to measure this one).

Don't Bypass the relay until you verify the fuse link. If the Fuse link is bad, then you also need to check the diode before you install a new fuse because if one of the diodes is bad it will simply blow the new fuse (and for something so small, those fuse links aren't cheap).......

flynhigherx · 08-03-2011, 09:36 AM

The continuity of the 50 amp fuse appears to be good.

The voltage between the white wire and the black wire is pack voltage, 37.4 VDC.

The voltage between the red and white wire is 37.4 VDC as well.

When I measured the voltage of the red wire on the cart side of the plug it was only 15.7 VDC. How is the voltage now 37.4 VDC on the red wire inside the charger?

JohnnieB · 08-03-2011, 11:00 AM

Quote:

Originally Posted by scottyb

.............I assume the relay is not clicking when you plug it into the cart, even if you lift and hold on the plug for 15 seconds?

flynhigherx, In your first post you said "The charger doesnt do anything, not a sound not even a hum!"

If the fuse and ammeter are good and relay doesn't click, you might be spinning your wheels looking elsewhere.

In the Plug from the charger, you'll see an Auxiliary Contact next to the Negative post. That is how the charger picks up the Negative to complete the relay circuit, and if it doesn't make contact, the relay doesn't energize and the battery charger doesn't turn on.
Steal an emery board from your wife stash and run it across the Aux contact a couple times. (Bending it a little closer to the Neg. post might be needed also.)

Here's what you need to get the relay to click: (Assuming the relay, ammeter and fuse are good)
Positive 28 volts or greater (Or something in that neighborhood) from the cart's battery (back-fed via the ammeter and fuse) and Negative from the cart's battery via the AUX contact.

FWIW: The function red wire in the Cart's charger receptacle is to prevent the Cart from being driven away while the charger is connected. The function of the red wire in the Charger Plug is to sense the presence of a battery and turn the Charger on. Neither wire has anything to do with the other.

JohnnieB · 08-03-2011, 11:33 AM

Re-Read the thread again.

If you haven't already done so, read all the STICKY:s at the top of the Electric EZGO forum and download the manuals in the bottom-most one.
The Service Manual has a schematic for a PowerWise charger on page K-6, which is page 142 of 228 in your PDF reader.

In your first post, you said you believed your cart was a PDS.
I see a Run/Tow on the controller cover in one of the pictures, so if it has a Forward/Reverse switch on the dash next to the key-switch, it is a PDS.
If the Forward/Reverse control is a lever under the driver's right knee, it's a DCS.

08-02-2011, 05:35 PM	#2
scottyb Happy Carting Join Date: Dec 2007 Location: Southern California Posts: 73,419	Re: 2002 EZGO will not charge I assume you checked the fuse inside the charger? I assume the relay is not clicking when you plug it into the cart, even if you lift and hold on the plug for 15 seconds? Is the 36v positive coming out of the charge receptacle on the cart side on the small red wire?

08-02-2011, 08:24 PM	#3
rabbitreborn Gone Wild Join Date: Jun 2010 Location: Central Florida Posts: 2,757	Re: 2002 EZGO will not charge After you verify the 50 AMP fuse inside the charger is still good...... Unplug the AC cord from the wall, pull the 2 black wires from the relay inside the charger and connecct them together. Plug the charger back into the wall and into the cart. Does the needle come up showing a charge?

08-02-2011, 09:27 PM	#5
flynhigherx Not Yet Wild Join Date: Jun 2011 Location: NC Posts: 11	Re: 2002 EZGO will not charge Rabbitreborn, How do I verify the 50 amp fuse inside the charger? I will bypass the relay and give it a try in the morning. My first reaction was to LMAO when you began with "first unplug the AC" however, I am more comfortable inside my 200 amp panel than inside the charger. With the charger unplugged is the capacitor the only thing that can tag me?

08-02-2011, 09:29 PM	#6
flynhigherx Not Yet Wild Join Date: Jun 2011 Location: NC Posts: 11	Re: 2002 EZGO will not charge Thanks guys for your really quick responses. I really appreciate your help fixing my cart!

08-02-2011, 09:43 PM	#7
rabbitreborn Gone Wild Join Date: Jun 2010 Location: Central Florida Posts: 2,757	Re: 2002 EZGO will not charge Believe it or not, I have never been tagged by the Capacitor (and I take risks while handling them all the time). The esiest way to verify the 50 amp fuse it to do a continuity check through it (It should be in line between the white wire and the back of the Anmeter). Basically you have a red (14 guage connectes to the black that runs to the PC board inside the charger), White and Black coming from the charger cord. you should see pack voltage across the black and white, Also, you should see pack voltage across the White and red (you can disconnect it from the black to measure this one). Don't Bypass the relay until you verify the fuse link. If the Fuse link is bad, then you also need to check the diode before you install a new fuse because if one of the diodes is bad it will simply blow the new fuse (and for something so small, those fuse links aren't cheap).......

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08-03-2011, 11:33 AM	#10
JohnnieB Techno-Nerd Join Date: Jun 2011 Location: West Virginia Posts: 19,654	Re: 2002 EZGO will not charge Re-Read the thread again. If you haven't already done so, read all the STICKY:s at the top of the Electric EZGO forum and download the manuals in the bottom-most one. The Service Manual has a schematic for a PowerWise charger on page K-6, which is page 142 of 228 in your PDF reader. In your first post, you said you believed your cart was a PDS. I see a Run/Tow on the controller cover in one of the pictures, so if it has a Forward/Reverse switch on the dash next to the key-switch, it is a PDS. If the Forward/Reverse control is a lever under the driver's right knee, it's a DCS.

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