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Old 10-19-2014, 11:17 PM   #1
jswiga
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Default charge and drive issues 2001 txt ezgo

Hello All,

Looking for some help. Charger wont turn on....What I have checked so far....

Charger is good. took to a cart place they plugged it into another cart and it worked.
I am getting 37.5 volts from the batteries, so I don't think its too low to read a charge.
I have replaced the receptacle on the cart and checked it, no corrosion or loose connections.

The cart was charging fine, one day it was stolen and flipped on its side. I cant say it was after that day things went wrong but that seems to be a point in time to start with.

So, what else is there to check?
Any help would be greatly appreciated.

FOLLOW UP:
The gauge was reading 1 bar from a full charge. I took it out and it was cruising for a minute or so. now it sputters. Almost feels like the motor is vibrating...
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Old 10-20-2014, 12:16 AM   #2
cgtech
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Default Re: charge and drive issues 2001 txt ezgo

Did you do a thorough cleaning job to clean the spilled acid from cart laying on its side, And checked water levels? How long was cart on its side? The amount of time it was laying on its side is the amount of time the battery plates were exposed to air, that is really bad for a liquid filled lead battery.
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Old 10-20-2014, 11:41 AM   #3
jswiga
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Default Re: charge and drive issues 2001 txt ezgo

It was only on its side for a moment or so tops. They immediately flipped it back drove down a hill then abandoned it.

The batteries all have fluid. It has been cleaned since this incident, July 3.
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Old 10-20-2014, 02:54 PM   #4
JohnnieB
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Default Re: charge and drive issues 2001 txt ezgo

What voltage is measured between the two terminals in the cart's charge receptacle?

What Make/Model charger?

----------
The cart is likely to be misbehaving due to the batteries not being charged.
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Old 10-20-2014, 03:06 PM   #5
jswiga
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Default Re: charge and drive issues 2001 txt ezgo

Quote:
Originally Posted by JohnnieB View Post
What voltage is measured between the two terminals in the cart's charge receptacle?

What Make/Model charger?

----------
The cart is likely to be misbehaving due to the batteries not being charged.
How do I get that voltage?
Plug the charger into the receptacle and take the cover off?

Sorry for the ignorance....I don't want to mess anything else up.
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Old 10-21-2014, 06:08 AM   #6
JohnnieB
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Default Re: charge and drive issues 2001 txt ezgo

Quote:
Originally Posted by jswiga View Post
How do I get that voltage?
Plug the charger into the receptacle and take the cover off?

Sorry for the ignorance....I don't want to mess anything else up.
The two exposed terminals in the charge receptacle are connected to the battery pack and are live 100% of the time.
Just measure between them with a voltmeter.
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Old 10-21-2014, 10:07 AM   #7
jswiga
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Default Re: charge and drive issues 2001 txt ezgo

Quote:
Originally Posted by JohnnieB View Post
The two exposed terminals in the charge receptacle are connected to the battery pack and are live 100% of the time.
Just measure between them with a voltmeter.
I get 36.5 volts from the charger receptacle.
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Old 10-21-2014, 10:19 AM   #8
JohnnieB
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Default Re: charge and drive issues 2001 txt ezgo

Quote:
Originally Posted by jswiga View Post
I get 36.5 volts from the charger receptacle.
That is lower than the pack voltage, they should be identical, so there may be some dirty connections between the receptacle and battery pack, but that is still high enough to turn on the charger.

Clean the outside of the Negative Radsok (left side facing the receptacle) and the auxiliary contact in the charger plug. (Item 36 on attached drawing)

---------
What make/model charger?
Attached Images
File Type: jpg Charger Plug - opened.JPG (40.8 KB, 0 views)
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Old 10-21-2014, 10:51 AM   #9
jswiga
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Default Re: charge and drive issues 2001 txt ezgo

Quote:
Originally Posted by JohnnieB View Post
That is lower than the pack voltage, they should be identical, so there may be some dirty connections between the receptacle and battery pack, but that is still high enough to turn on the charger.

Clean the outside of the Negative Radsok (left side facing the receptacle) and the auxiliary contact in the charger plug. (Item 36 on attached drawing)

---------
What make/model charger?
Cleaned the receptacle and the aux contact. Getting 36.5 volts from the receptacle and the batteries themselves, so they are the same now. but still no charging.

Charger is a powerwise 28115 G04.
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Old 10-21-2014, 12:22 PM   #10
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Default Re: charge and drive issues 2001 txt ezgo

Quote:
Originally Posted by jswiga View Post
Cleaned the receptacle and the aux contact. Getting 36.5 volts from the receptacle and the batteries themselves, so they are the same now. but still no charging.

Charger is a powerwise 28115 G04.
That is odd. The charger works on a different cart, but not on yours.

The way the charger is turned on, is that the voltage from the cart's battery pack energizes a relay in the charger, which connects AC power to the transformer's primary.

The way the cart's pack voltage gets to the charger's relay is the auxiliary contact in the charger plug touching the outside of the negative radsok in the cart's charger receptacle. The auxiliary contact in the plug is connected to the control board in the charger via the third (smaller) wire in the charger output cable.

When the charger is not connected to AC power and plugged into cart, measure the voltage between the red and black wire on the control board. It should be pack voltage.

If it isn't, there is an open someplace between the black wire on the control board and the main negative terminal on the cart's battery pack.

---------
There is the possibility the there is an intermittent open that just happened to be closed when charger worked on other cart.

Here is a schematic and manual for the charger
Attached Images
File Type: jpg PW Charger Schematic.JPG (47.4 KB, 0 views)
Attached Files
File Type: pdf PW Charger manual.pdf (3.02 MB, 0 views)
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