ezgo total charge shutting off early

[3WheelDumbo]

EZgo total charge stops charging at 41.5v as measured over the battery pack. Is this right??? and if not can I bypass the shutoff?? so i charge it on time only??? help.

Thanks guys.

i can't answer this but let me suggest this
after charging and unit shuts off .. give it 5-10 min then plug it back in and see if it restarts and if it does see if it charges to a higher voltage when it shuts off .. also make sure meter is correct

[3WheelDumbo]

Yeah been doing that one... That's how I got it to repeat the 41.5volts. I think this is low.... Where's Johnnie the tin man? I've seen him post on this stuff before

[skuhleman1524]

Mine will randomly shut off. Sometimes it will go the full 11 hours. Sometimes only 20 mins. On equally disharged battery levels. I figured out that you have to have the charger connector plugged into the cart just right or it will have problems. If I get it in there right it charges correctly. And shuts off properly.

[JohnnieB]

Sounds like you've either got excessive resistance in the charging loop, or a bad control board in charger; And I suspect it is the former rather than the later since control boards tend to either work correctly, or not work at all.

The first attachment is a wiring diagram for a Geenface Total Charge and the second is same drawing with some wires highlighted.

The wires highlighted in red and blue are the wires the feed the on-charge voltage to the control board and it is this voltage that actually shuts off the charger when it reaches about 45V.

The voltage you are measuring (41.5V) is at the distal end of the purple and green wires, so there may be enough resistance between where those wires attach (Negative at ammeter and positive at heatsink) and the main battery pack terminals to drop 3.5V when there is about 2A of current flowing.

The five high current cables that connect the six batteries in series, might or might not have issues, but any voltage they may be dropping is included in the 41.5V measured at the main + and - battery pack terminals, so they are not causing the symptoms being seen.

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Unplug the charger from AC power and remove the cover from the charger, then monitor the voltage on the red and black wires going to the control board (Heat sink and Ammeter would be the easiest places to connect test leads).

If it reads 41.5V (or same as voltage at main battery pack terminals) the control board is defective.

If it goes up to about 45V like it should, there is a resistance problem with the connections and components between the ammeter(-) and heatsink(+) and the main +&- terminals on the battery pack.

[3WheelDumbo]

You rock Johnnie, thanks that's exactly what I was looking for.... how to test this thing. From your description I'm assuming its excessive resistance as non of the wires have been upgraded and some of them look fairly small, plus the age of the batteries, the charger seems to work to consistantly and is really clean for it's age. Will test it tonight and let ya'll know.

[yurtle]

You already mentioned problems in the charger plug. I'd tear it apart and clean it good. Both plug and receptacle. Short of that, I'd hit it with a spray cleaner and plug and unplug several times.

The voltage sense wire is separate on some chargers, so it may be dirty.

Look in the stickies for a manual.