Category: Battery Charger Knowledge

Why Isn’t My Golf Cart Battery Charger Working

Quite often people plug in a brand new charger and it doesn’t come on or light up or do anything they expected.  Nine times out of ten this is because the batteries are too low.  There is a safety feature in most new golf cart battery chargers that require them to detect a voltage before applying amperage. This means they want to know the DC side connector is plugged into the receptacle for the battery bank. Otherwise that connector could be dropped in the puddle you’re standing in (not good) or cause some sort of unexpected harm. A lead acid battery will lose about 10% of its capacity each month.  So if a cart is left for an extended period (at a vacation house or put away for the season up north) then the batteries could have drained too low for the charger to detect them. This is quite common.  On average a 48v charger needs to sense between 25-35 volts to turn on.
If this has happened to your cart, you will need to use a common automotive charger for 6v, 8v or 12v batteries and charge them up individually.  It is not necessary to disconnect the batteries from each other or from the cart.  Simply put the positive and negative leads on each battery one at a time.  This type of charger will not stop charging (as the golf cart charger knows how to do when the battery bank is topped up), so be careful not to leave it going.  We usually say 20-30 minutes per battery depending on how low they are.  Once this is done, the charger should detect them and be able to maintain them.  Yes, most folks don’t understand why they need to use another charger to charge their batteries when they just bought a charger to charge their batteries.  But you certainly don’t want to charge each one each time, and you don’t want to have to set a timer to do it.  Using an automotive charger is a one time thing to give them CPR so the golf cart charger can maintain them all at once and hassle free.
If you have a voltmeter telling you the batteries have enough juice, or if the cart runs and drives fairly well as it is, then check the receptacle.  There may be a break in the system.
We recommend that every charger be plugged into a surge protector as they are very sensitive to power surges and lightening strikes.  Usually any cheap power strip will do as long as it will trip before the surge reaches the charger.  If your charger has been working fine but stopped after a lightening storm or a power outage, that may be the culprit.  This actually will void the warranty, so it’s important to protect them.

How To Pick The Right Golf Cart Battery Charger For Your Golf Cart?

First things – first. When your golf cart battery charger stops working you will need to determine why. It is also important to know because it is not always the charger that is bad. There are a lot of common problems that can cause your golf cart battery charger to stop working. Most common are things like the AC power supply has been interrupted. ( Power Surge, blown or popped fuse or breaker ), DC side voltage to low – Meaning the batteries in your golf cart are so low the charger does not know it is even plugged into your golf cart to start to charge. See our FAQ for more in depth information on this scenario and how to remedy the situation. If these are not common problems related to why your charger is not working you will need to move forward with your search. Pete always recommends checking the conductor wires between batteries. They are all connected to create the combined power supply for your golf cart. If one is bad or lost connection with the batteries it will cause everything to stop working. So if your golf cart is not moving anymore this could be the culprit. Or could just be the wires going from the charger receptacle to the batteries on the cart where you plug in the charger. After these basic searches have been done you can assume the worst ( your charger is dead ) and now you need to start looking for a replacement. Things to know before you start the search.
  • What year, make and model golf cart do you own?
If you do not know you will need to find out what kind of golf cart you have. The big three makes are Club Car, Ezgo and Yamaha. There are numerous ways to determine the make and model. Usually you will find some sort of branding or badging on the golf cart. The determine the year or model specifically you will usually be able to find a serial number sticker ( On Club Cars above the pedal assemble under the dash or on the passenger side dash support upright – which looks like a white sticker with a barcode on it) Ezgo carts you can usually find a serial number plaque inside the passenger side glove box area. Yamaha depending on the year and model are usually somewhere under the seat in the battery or engine hold area. Note – this step is usually only required to make sure you get the right charger for the Club Car carts that use the round three pin charger connectors because some carts (between 1995 and 2014 have a OBC or Onboard computer to tell the charger when to turn on and turn off)
  • What is the operating voltage of your golf cart?
This is easily determined by looking under the seat of your cart and counting batteries and cell caps. For example if you count six (6) batteries and each battery has three (3) round caps on each you will now know those are 6 volt batteries. So 6 x 6 volts = 36 volt system. So you would need a 36 volt golf cart battery charger. ( The voltage of the cart must match the voltage output on the charger you purchase.) On 48 volt golf carts some come with four (4) batteries which are 12 volts each. Or six (6) 8 volt batteries. Again this can be determined by the individual cell caps on each battery. A 12 volt battery will have 6 and a 8 volt battery will have 4. All golf cart batteries are comprised of 2 volt cells. So being a 6 volt battery will have 3 cells, and a 8 volt battery will have 4 cells then lastly a 12 volt battery will have 6 cells.
  • Confirm and compare the connector the you will plug into the golf cart charging port.
Basically you can determine all thee above by just knowing what connector your current golf cart battery charger uses. Though is is wise to double check by looking under the seat and counting batteries to be sure. This is basically because most people buy the golf cart used and do not really know what the previous owner did to it. We have seen numerous times where a customer had a charger that used a 36 volt plug on a cart that was converted to 48 volts.
  • Popular Connector Shapes and Styles and what they represent.
Club Car Golf Cart Battery Chargers have either a crowsfoot connector which means it is older and came as a 36 volt golf cart. or a round three (3) pin connector which means it is a 48 volt golf cart. Ezgo golf cart battery chargers will also use a crowsfoot connector which meansd it is also an older cart and 36 volts. But they also use what is known as a D36 or TxT connector that is rectangular shaped and rounded on one side with two round pins one inside each of two slots in the front of connector. This is also a 36 volt connector used on the popular TxT model golf cart. Now if you have an Ezgo golf cart that has a rectangular 2 pin connector with a slot cut out right down the middle or a triangular 3 pin connector you have a newer style 48 volt golf cart. Yamaha golf cart battery chargers are also found with a crowsfoot connector which means it is again an older cart and 36 volts. ( Prior to 1990 alot of the golf carts manufactured where 36 volt systems and all used the crowsfoot connector system.) But usually Yamaha golf cart today are all 48 volt systems. One uses the Nabson plug connector which looks like a fisher price pair of toy binoculars. 2 pin design. Or the newer Drive carts came with a 3 pin connector that looks kinda like a three leaf clover. or some say a square with rounded edges. either way these are 48 volt systems.
  • What if you cannot find the connector on the battery charger or see that it is wired directly to the batteries on the golf cart?
No Worries. This just means your golf cart has what they call an Onboard battery charger. So you will need to either locate the charger itself and read the specifications off the charger or count the batteries and the cell caps as described in this article above. Either way it is still not big of a job to replace the charger in your golf cart. Most are very straight forward and easy to install and use. Most common today are the Delta Q brand chargers found in onboard applications on carts like the Ezgo or the Tomberlin brand golf cart. Lester electric actually has a great new onboard battery charger called the Summit Series II which even comes with Bluetooth connectivity. So times are changing and the golf cart battery charger of yesterday is almost gone as companies make newer safer more efficient chargers. Which is great for the golf cart owner because some are even designed to charge or maintain your batteries while you are away on vacation or elsewhere for long periods of time.
  • Use Pete’s easy to navigate golf cart battery charger section to find your charger.
Pete offers all the major brands of golf cart battery chargers at reasonable prices and all ship free in the United States ( Lower 48 Only) Find yours today and SAVE BIG!!!!

Frequently Asked Questions About Your New Golf Cart Battery Charger

Dear Pete, Hi, finally this week we got the charger. However; once plugged to both the outlet and to the golf cart no lights come up, is this normal? Batteries haven’t been charged in a while. Confused… Terrific… Glad to hear you finally received the charger. Though in order for these chargers or any new style charger to function they need to be able to pick up voltage from the cart. If the batteries are completely dead or near so the charger will not kick on. You will need to charge the batteries up individually with like an automotive style charger, two at a time if you have a 36 volt battery system, or even can do 3 at a time if you have a 48 volt system and a automotive style charger that allows you to toggle charge voltage like 6v, 8v, 12v, or 24v. Once the bank of batteries is at least 35-40v plug in the new charger and it should do its thing. Regardless of how you do it the battery bank needs to be charged up enough for the new golf cart battery charger to know it is actually hooked up to a battery bank comparable the operating voltage of the golf cart charger you purchased. Once this is achieved should be able to use the new charger as intended. To get the most out of your batteries… Always charge your batteries back up after use and before storing. This is also the time to check the water level in traditional lead acid batteries. (After they are completely charged.) Pete
Pete… Super fast shipping thanks, Question? I received the new DPI 36 volt golf cart battery charger this morning. I started charging the batteries and everything was working fine. I came back to check if it had finished charging and the charger was hot, the amp meter was still showing close to 20 amps. I checked the battery volts with a volt meter and it showed 45 volts. I unplugged the charger from the wall outlet and disconnected the plug from the cart. I again checked the voltage and it was still at 45 volts. Is there something wrong with the charger or is this normal? These are new batteries and I don t want them ruined.   Yes sir…. All seems to be fine… These types of chargers do generate heat. Really any device that is passing and converting current (electricity) thru it will do so. That’s why they are made with Aluminum casings and have holes punched throughout the case to help dissipate the heat. New batteries right off the line are very hungry for energy and will soak it up like a sponge for the first 15-20 charge cycles… the lead is not cured yet… I have seen new batteries right off the line take a charge for 8-12hrs… usually starting out with amperage up around 15-20 range (Wide Open) then as the charge cycle reaches higher voltages the amp gauge will start to go down. but still might stay in the 5-10 range for hours still. These chargers are designed to shut off automatically when charge is complete so let it run its course… I do suggest venting the area if charging in a garage or shed vs out side because off gasing does occur during the charge process of lead acid batteries and kinda stinks. Note – a fully charged 36v cart is usually around 42-43v… but during the charge process as the charger forces electricity into the batteries the voltage will be higher. Same applies to a 48v system where there you will see voltages well over 50 volts… Hope this is helpful in better understanding your golf cart battery charger and batteries. Power On… Pete Just got my new golf cart battery charger in the mail. Super fast shipping but it doesn’t work either. my other charger just stopped working so I assumed it was the charger. Could there be something going on with my golf cart? The kids used it all weekend and ran it down to the point we had to push it into the garage. We plugged in our old charger and nothing. Here it has been a week and still cannot use our golf cart. Any ideas? Thanks in advance , Steve. Well actually you probably did not need to purchase a charger at all. Sounds like the batteries in the golf cart are just so low when you plugged in the battery charger it did not know it was plugged into your golf cart and just did not turn itself on. You see all new style chargers have to sense voltage before they will apply amperage. It is a built in safety feature so you cannot electrocute yourself or someone else once the charger is plugged into the wall socket. On average a charger will need a surface voltage of 30 volts or better in the golf carts battery bank to turn itself on. So if you do not have enough electricity in the golf cart batteries you will need to charge them up manually with a 6 or 12 volt automotive style battery charger. You do not even need to disconnect the wires just attach the clamps red to positive and black to negative on each individual battery for 10-15 minutes each to get some energy back in them. once you have done this across the whole bank. try your old charger first to see if it works. If so you can return the new one and we will credit your account minus the shipping costs to send to you. Hopefully this is the problem. It is a very common thing where people forget to charge the batteries in the golf cart before they go away for a few weeks. Or go away for the summer months to return to a dead cart. Pete… Thanks Pete for the fastest delivery I have ever had. I have installed my new Delta Q QUIQ 48 volt golf cart battery charger and everything is working. I have a question about the charger. Will it hurt the charger in any way if I connect a Battery Life Saver Battery Desulfator for 48V Golf Carts BLS-48N and leave in on all the time? Will that in any way harm the charger? Thanks again for the great service. Francis H. Zane – Thank you for your business. Though, I do not believe in those things (Battery Desulfators)… plus always applying amperage to a battery is not good either… If you do I would disconnect the DQ – only because I have never tried to hook one up with the QuiQ charger installed and doing it’s thing. This charger alone should take care of your batteries just fine… and has a low voltage Auto charge so just leaving it plugged in will allow the charger to keep your batteries in good health. The best sulfation solution is to just exercise the batteries – charge/discharge on occasion and store fully charged… You could throw in a teaspoon of Epsom salt on each cell once a year will keep the plates clean as a whistle… Power On… Pete Pete please help…. Hi i charged my cart with my new charger. Thanks for the fast shipping but the batteries folded expelled acid do i have to change the settings on the charger my batteries are Trojan t-875, 8 volt, 170 ah @ 20hr, 145ah @ 5hr No Worries – You should be fine with the factory setting…These golf cart chargers come pre set for lead acid batteries and your Trojan batteries are well within the settings range. It sounds like the batteries where over filled. Always check the level of the electrolyte after batteries are fully charged and only fill each cell about 1/4 – 3/8 inch above the batteries plates… which leaves about equal distance to the bottom of the cell cap tube. Pete’s Team TM006

How to Install New Input Control Board On Your EZGO Powerwise Charger

This Blog article is to help ease the installation of your new Ezgo Powerwise charger control circuit board. We are talking specifically about the 28667G01 Ezgo OEM Powerwise input control board. designed specifically for the Ezgo Golf Cart Powerwise Battery Charger shown below. Manufacturers part numbers 28732G01, 28732G02 and 28115G01 – G11. These chargers where found on all Ezgo vehicles from 1994 to current that operate with a 36 volt battery system and utilize the TxT 2 pin connector. Also known as the D36 or Powerwise plug.
Ezgo Powerwise Charger Image
Ezgo 36 Volt Powerwise Golf Cart Battery Charger
This is going to be a fairly straight forward installation and you will only need a few basic tools. Tools required:
  • Pliers
  • Needle Nose Pliers
  • Screw Driver
  • Heat shrink or Electrical Tape
Ezgo Powerwise Charger Illustration Exploded View INSTALLATION INSTRUCTIONS : 1. Remove the AC plug from the electrical outlet and the DC plug from the vehicle receptacle. 2. Open the Charger Cover (1) by removing screws (2). Retain for installation later. 3. Make a note of the location and color of each wire before disconnecting the wires from the Input Board-Power Control; be sure to connect the wires to the new Input Board-Power Control in the same location that they were removed from. 4. Remove the Input Board-Power Control (3) by removing the spacer supports (4). Discard the old Input Board-Power Control (3) and retain the spacer supports (4) for installatin of new Input Board-Power Control (3). 5. Installation is in the reverse order of removal.   IF THIS WAS A HELPFUL HOW TO BLOG POST PLEASE LET US KNOW. COMMENT BELOW AND LET US KNOW ABOUT YOUR SUCCESSFUL INSTALLATION.  Need a new 28667G01 Ezgo Powerwise Input Circuit Control Board in your Golf cart Battery Charger.