EZGO POWERWISE CHARGER REPAIR OR REPLACEMENT
We get customers all the time that ask us the tough question. Should I repair my Ezgo Powerwise Charger or just replace it? This is something that Pete usually says… “If it is an electrical component and you are not an electrician or seasoned tinkerer just replace it.”
When it comes to spending time and money on something that you find yourself just standing there afterword with your fingers crossed hoping it will work – it is best to just replace the charger. Now this comes with a few other caveats because when customers call over the phone and try to explain the problem it has numerous possible causes being the charger needs to rely on the golf carts charging system to be operational as well in order to turn on. Several factors on the golf cart itself can cause the charger not to work or kick on.
So if you want to take a stab at fixing or at least diagnosing the problem read on…. The biggest one is a completely dead cart. If the batteries in your golf cart are so dead the cart will not run and drive as intended you will need to charge each battery individually with like an automotive charger with clamps to revive before your Ezgo Powerwise charger will kick on if it is operational. Now you can also have a bad connection, a blown fuse or a wire in the charge circuit that is not completing the circuit. The easiest way to determine these few things is to get a voltage meter and check a few basic connections and the overall voltage of the golf carts battery bank. When you have six new 6 volt batteries combined in a circuit you will have approx. 38-39 volts. If the cart is not running and driving the voltage is most likely well below 30 volts and possibly why the charger will not turn on. With your handy volt meter you can check this and tick off the box. Yes or No?
Next step would be to determine if the charge circuit is still complete? Take the positive and negative pins from the volt meter and insert in the cart side powerwise charge receptacle. You should have the exact same voltage you have at the positive and negative most terminals on the battery bank. Example – If the cart has 37.8 volts at the batteries, then you should have 37.7 – 37.8 volts at the charger receptacle. Yes or No? If yes then the charge circuit is complete and the problem could very well be your Ezgo PowerWise Charger. Now if you don’t get the same voltage you will need to back track the circuit from the charger receptacle to the batteries. Double check all the wires going back to the batteries… work your way backwards with the volt meter until you can narrow down the fault. Golf Carts are fairly easy to work on so it should be obvious enough once you can narrow it down a bit and start looking around and chasing wires. Could be as simple as an in-line fuse.
Now if all checks out:
- Running and driving golf cart
- Advertised operating voltage. (In this case 36v or greater)
- 36 volts + at the battery terminals
- 36 volts + at the charger receptacle
Time to check the charger further. If possible see if someone has another 36 volt Ezgo golf cart in your neighborhood with the same TxT 2 pin connector. Plug in to see if your Ezgo Powerwise charger works on their golf cart. If not then you can just get out the tools and start taking it apart or plan to replace it. Usually with these older style transformer based golf cart battery chargers we find they are corroded due to extended periods of time left out in the elements. Some other issues occur when a lighting strike takes place and it can cause a Power Surge that will burn something up quite fast. Usually a fuse will pop first if you have a fusable link in the charger circuit but most chargers do not as is the case with your Ezgo powerwise charger. Pete recommends using a power strip with a breaker built in to plug your charger into to avoid this common issue in South Florida. The power surge will just pop the breaker on the power strip but save you about $500 – $1000 dollars depending on what kind of cart you own. So next in line is the most common internal part to fail over time is the Ezgo Powerwise Charger Circuit Control Board OEM Part#28667G01
If all other possible issues have been checked and are ok this is usually the problem. It is a fairly simple thing to replace with basic tools like pliers and screw drivers. Should you purchase one and want to learn how to install one here is a how to article that covers the installation
Though there are a few other internal components that can cause malfunction or charger not to work. Things like the transformer itself – or relays. Sometimes it is a relay which is easily checked but transformers rarely go out unless the charger got really wet and just shorted out or got corroded over time. Repairing anything is a process your golf cart battery charger is no different.
Usually this is where I ask myself should I bother to try to fix it or just buy a new one? If I use it often and need reliability I would just buy a new Ezgo Powerwise Charger
so I don’t get stuck or worry about if my charger is charging my batteries over night so I can play a round in the morning or not. Or burning up my batteries because it just doesn’t ever seem to shut off. I got plenty of other things in life to worry about. If I can just buy new from guys like Pete I will. Pete not only has great everyday low prices he also has a great Free Shipping Policy – All Orders Over $99 Ship Free! Pete only offers global brands you already know and trust. He just does it For LESS! He actually stocks ALL the major manufacturers of golf cart battery chargers like DPI, Delta Q, Lester Electrical, Pro Charging Systems, and Quick Charge. So if you are looking to just replace your Ezgo golf cart battery charger
follow this thread or continue reading about your golf cart charger and learn about other things you should know
Is My Golf Cart Battery Charger Over Charging My Batteries?
This question was asked by a customer of our the other day and Pete wanted to share this information with you as well because it is a question Pete has found himself explaining over and over again over the years.
Question: From Rick in Florida.
”I have a new links charger and it seems to be over charging the batteries. The batteries were bubbling and the charger was still running. Charging at about 5 amps. 2 hours after I disconnected the charger batteries read 12.94
V Batteries are new Trojan 1275 Any suggestions ”
The Lester Electric Golf Cart Battery Charger you purchased is a transformer style charger that is designed to apply amperage and voltage for a length of time that replaces the energy used from last discharge. This is fairly old technology but very effective to charge your golf cart batteries. Depending on the battery chargers output (Amperage), the batteries size (Capacity), and DOD(depth of discharge), all this will determine the amount of time required to fully charge the battery bank in question. In the process as they reach maximum capacity the more electricity that is forced into the batteries the more it excites the electrolyte and gets electrons moving in the battery itself…(That is the boiling sound you hear)
This is common… especially with NEW batteries…. this process actually needs to happen to positively charge and electrify the lead plates and cure the new lead…. any new battery pulled off the line at the manufacture will only test out at about 80% advertised Ah rating because the lead hasn’t been cured (still to soft). Something that is really impossible for the manufacturer to do in house because of the process involved. It takes on average 15-20 cycles at 50% DOD “Depth of Discharge”, to completely cure the new lead plates in a new lead acid battery and allow the battery to reach full capacity (That will be the advertised Ah rating at the 20hr rate.) So no worries as the charger is just doing its thing… Trojan batteries actually like to get hit harder ( More Amperage applied) than others thru the bulk phase and finishing phase of a charge cycle because the lead plates are thicker than most competitors. You will most likely add more water than ever over the period of time we will call breaking in phase. This is from the charger forcing electrons into the lead, once the lead is cured electrons cannot pass thru as easily. At which point the batteries will not be as excited (loud boiling sounds) when charging/complete charge. Make no mistake lead acid batteries will always make noise in the charge process and finishing phase because of the specific chemistry and design that make a lead acid battery. It is also an important part to insure good battery health as well. Without this boiling the lead plates sulfate rapidly and severely hinder battery life per charge and cycle life. This process actually helps to clean the lead plates and keep them clean to better react to the electrolyte in the cells to create electricity. AGM and Gel style batteries are even more picky than traditional lead acid batteries because they like more voltage and amperage to complete the same process.
Hopefully this was helpful and insightful to ease your worries about your golf cart batteries and the golf cart battery charger.
Rick – response
Thanks for your response. So I understand the bubbling and sulfur smell are normal and I should not disconnect the charger. What should the Voltage be when fully charged? Should I charge even when reading about 12.5 volts after 9 holes?
Pete – response
No worries … I have seen 48v systems run as high as 58-60v when charging, but it is normal to see voltages around 50v-52v when sitting static for several days after a fresh charge cycle. Most common size lead acid batteries will be from .6 volts to .8 volts over advertised voltage on battery when fully charged. Always good to re-charge cart at the end of the day, never let it sit 1/2 -3/4 charged. re-charge then store when not in use.
How To Reset The OBC On My Club Car Golf Cart
All Club Car golf carts newer than 1995 have an OBC or ” On Board Computer ” in the charge circuit to monitor and control several functions on the golf cart. It functions like the on off switch on your wall to control the lighting. But in this case it controls the charging and drive system. If the OBC detects a problem in either the charging or drive system, it will shut that feature off. When the fault clears, the OBC is supposed to turn that system back on. Sometimes, the OBC does not clear the fault. When this happens, it can cause your charge circuit to not work and allow the charger to charge the batteries, or even the controller not power up or the solenoid will not engage.
The reset process is easy to do, but can take a fair amount of time.
Resetting the OBC
To reset the OBC the following must be done in this order:
• Key Switch to Off
• Forward/Reverse to Neutral
• Tow/Run Switch to Tow
• Disconnect the Battery NEGATIVE (–) wire from the Battery Minus terminal on the battery pack.
• Put the Tow/Run to Run
• Forward/Reverse Switch to Reverse
• Key Switch to On
• Lock the throttle pedal down
The reverse buzzer will then sound and shut off in roughly 30 seconds. Leave the cart for 5 min or so to allow the OBC to reset.
To reconnect the OBC back into the system:
• Key Switch to Off
• Forward/Reverse Switch to Neutral
• Tow/Run switch to Tow
• Reconnect the negative battery wire to the battery minus terminal on the battery pack. Once the OBC has been reset, you can trouble shoot the golf cart. There is always a chance the OBC has completely failed and the reset process will not fix the problem. Consult your Club Car manuals or call your local dealer.