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Unread 09-05-2011, 08:06 PM   #1
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Default 36 volt powerwise ez go charger not working

I recently had an issue with my batteries going dead on my 36 volt Ez Go golf cart. I had the batteries tested and was told I needed new ones. I replaced them and the cart still did not work. After talking to the Ez Go dealer it was determined that I needed a new computer controller. I ordered and replaced the controller and the cart worked. Now when I try to charge the cart my charger won't cut in. I checked my battery voltage and I have 35.02 volts. Any ideas why the charger won't cut in? The charger model number is 28115 G04.
The golf cart is an EZ GO late 90's model with a 300 amp DCS controller P/N 73144 G06. All I can find on the golf cart for identification is a plate with a Manuf. Code H0397.
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Unread 09-05-2011, 08:11 PM   #2
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Default Re: 36 volt powerwise ez go charger not working

You may not have enough volts for the charger to kick on.
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Unread 09-05-2011, 08:32 PM   #3
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Default Re: 36 volt powerwise ez go charger not working

I have been told 31.5 is the needed voltage for the charger to read and function. You could have worn pins in the charger plug. Try holding up on the plug for a min. after plugging it in.
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Unread 09-06-2011, 01:50 AM   #4
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Default Re: 36 volt powerwise ez go charger not working

H0397 = Manufactured in Mar-97
That means you have a 1997 TXT DCS

35.02V is sufficient to turn on the charger, but your new batteries have been discharged down to 20% and will be ruined if they are not charged ASAP.
DO NOT attempt to Run your cart with the battery this low. Doing so will destroy your new controller. (DCS + Low Voltage = Blown controller)


Plug charger into AC Power, then plug into cart.
Does the relay click after a 3-4 second delay?
If it does, you might have a blown fuse, which usually means the diodes are shorted.
If it doesn't, either it isn't sensing the battery voltage or the control board is bad.

Plug it into the cart as described above and let us know exactly what you see and hear. IE: Relay click - Transformer hum - etc.

I don't suppose your dealer mentioned new batteries need to be fully charged before they are used.
Or that they need to be "Matured" to reach full storage capacity.
Or that the closer you keep them to fully charged, the longer they last.

If you have a 12V charger, charge you 6V batteries two at a time to get that voltage up to at least 6.1 or 6.2 per battery, hopefully before irreversible damage is done.
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Unread 09-06-2011, 11:45 PM   #5
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Default Re: 36 volt powerwise ez go charger not working

When I plug in the charger I hear nothing. When you say control board, do you mean control board on the charger? The dealer that sold me the batteries told me they were fully charged. When I first got them they read 37.2 volts. Is that not enough or should they have been reading higher?
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Unread 09-07-2011, 12:52 AM   #6
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Default Re: 36 volt powerwise ez go charger not working

You dealer is blowing smoke. They were have charged and are now below empty as Johnnie Stated. The charger has a relay. Simply take it to the dealer and ask him to test it on one of his carts. That way we know if the problem is with the charger or the cart without a lot of work...
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Unread 09-07-2011, 10:58 AM   #7
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Default Re: 36 volt powerwise ez go charger not working

Quote:
Originally Posted by rmortens View Post
1. When I plug in the charger I hear nothing.
2. When you say control board, do you mean control board on the charger?
3. The dealer that sold me the batteries told me they were fully charged. When I first got them they read 37.2 volts.
4. Is that not enough or should they have been reading higher?
1. That means the charger isn't sensing the battery in the cart.
Like Scotty said, if you can, try the charger on a different cart.
That should narrow down the battery charging problem down to either the charger or the cart and we can proceed from there.

2. Sorry I wasn't clear. Control board in the charger. (The electronic speed control unit in the cart is commonly referred to as the "controller".)
The control board in the charger senses battery voltage and activates the relay that applies AC power to the transformer if the voltage sensed is above a predetermined level.
The sensed battery voltage climbs as the battery accepts the charge.
When the sensed voltage climbs to a level that indicates a full charge, the control board deactivates the relay.
The control board also has a safety timer that shuts off the charger if the sensed voltage doesn't reach the cut-off voltage within a predetermined time limit.

3. For whatever reason, the dealer was mistaken. 37.2V is about 70% charged.

4. Most, or at least many, cart owners try not to discharge their batteries below 70% and never discharge them below 50%. At 35.02V, your batteries are at 20%.

Go to to Scottyb's website (Carts Unlimited) and read everything he has there about batteries.

Attached is a chart showing Battery Voltage vs State of Charge.
Attached Images
File Type: jpg batterytable1118242f71.jpg (43.1 KB, 7 views)
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Unread 09-07-2011, 11:07 AM   #8
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Default Re: 36 volt powerwise ez go charger not working

check the read switch at the plig in for the cart. that has to read batt voltage other wise the cart wont move. you can test by jumping the wire to the pos sid of the batt teminal reading 36 v if it works there is a problem with the wire or could just be a bad conection in the plug box at the cart. hope it helps have had this problem before. also make shure the wire for the read is hooked to the batt and didnt get over looked when switching out the batts
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