Powerwise Charger Board and Diagnostic | How to Repair or Replace Golf Cart Charger

[@lorddabber3016]

This guy is great! Actually, let me rephrase that, this guy is FANTASTIC!

[@karenranda3304]

I'm so happy, I DID IT. I don't like working with electricity and at 69 years of age, I've had my share of shocking episodes. After putting the new charger board in I plugged it in and tripped the breaker.....I took the cover box off again and watched the video frame by frame. I found where I had misplaced two black wires. Now,,..my heart is happy. It works great. Karen Randa

[@MeimJust]

Without doubt, one of the best walkthroughs I’ve ever seen. Fantastic.

[@timbarker5663]

Thank you!!!! Guys like you save me SO much time and money with all my projects. I really appreciate you taking the time to make this so well and sharing your knowledge. Many many thanks

[@capnchip]

This is a VERY GOOD video about chargers for golf carts. It is the very best I have seen. Mine quit recently and I feel certain I can NOW fix it. THANK YOU SO MUCH!

[@golfcartking]

Great!! Glad I could help! Thanks for watching and don't forget to subscribe.

[@tbone6826]

I have ABSOLUTELY no electrical experience. Took my charger to my local golf cart place Charged me $25 just to look at the thing. Was told I had a bad capacitor and motherboard. They wanted $119 for the motherboard and $48 for the capacitor parts price and an additional $40 for labor on this 15 minute job. Ordered a kit that included motherboard capacitor fuse and diodes for $115 shipped. Long story short this video saved me $100. Only gripe I have is the end as your plugging all the wires back in.. by giving a wider angle would have helped. I found myself waiting for the perfect time to pause to check my connections. Thanks for your help!!!

[@golfcartking]

Thanks for watching!!

[@christinaswope3575]

Your video actually motivated me to troubleshoot my charger and found that it was the relay!! Thank you!!!

[@tbobtrasman4875]

Thanks for this video. I am now a certifiable... I mean certified golf cart charger repair guy. Yeah that is it. Certified. Remember... Take pictures then take apart. And always order parts THAT COME WITH INSTALLATION INSTRUCTIONS!!!😊

[@joannsullivan7057]

Great video My charger doesn’t shut down when fully charged Please advise what to swap out

[@karenkeim1064]

Thank you!!!!! I brought my charger in next to the computer and went through each step with you!! It's the relay. I built a bypass wire as you suggested and got my cart charging now, and a new control board ordered!! I have the older version so I guess I will have one board now instead of two. Anyway......Thank you again, you were a great help! Excellent video!!

[@rebeccamanuel3422]

Thank you so much! I was able to save a ton of money because of your video.

[@techbytesontario]

this video was excelllent! thank you soo much for putting this out. I have tested my capacitor and got 1.9-2.0 would that be considered bad for this particular capacitor? is that outside the margin of error? thank you

[@BrandonDickenson35]

What a great walkthrough on this charger. I had already tracked my problem down to the relay/solenoid when I didn't hear that firm click the charger used to make and saw that it was in there. However I was questioning the cap because this charger has been stored outdoors and looked very poorly, but your specs tell me it's in fine operational range after all of it's hard life. Someone new to electronics can pick up a dmm user manual and this video to diagnose their issue. Hope your able to stick to teaching because you've a knack for it

[@garymallett6550]

I changed out board with a new one no charge it charges if I jump across thanks for your help

[@MarshMarlowe12]

Great video. My charger doesn't seem to charge my batteries long enough. Always shuts off within an hour or so. Capacitor?

[@johntrejo9070]

Thanks so much ! Really clear to understand the troubleshooting procedure , you made it so easy - now feel more confident working on this device 👍

[@BobDeath22]

Thank you for sharing, I have learned so much from your videos.

[@zachdove3058]

Wiiw wie,jeiejj

[@barbaradavies1198]

Thank you Barry!!!! You have saved me lots of money!

[@RyDoggys]

Thank you. Saved a bunch of time and money. Great video.

[@shaunmoon8700]

Great video!! I love the troubleshooting to eliminate all possible options and found my board bad. Thank you!

[@ricksavage2819]

My charger board has brown and orange leads on the old board and red and black leads on the new board what do I do with the brown and orange wires

[@iman48]

Great teacher now I know how to check it

[@golfcartking]

Thank you!! Don't forget to subscribe!!

[@bobsanders1769]

Great video Went thru the testing and came up with a bad relay on the charger board, Got confused when I went to purchase new board. My Charger is a 28115G04 The board says 9012 but I can't find the right replacement number. Can you tell me what Board Number to order. Thanks

[@taylordunnusedcarts6902]

Your video are very clear and precise! I have learned a lot and are very understandable. I was looking for a Fluke meter that had a load tone when checking continuity and I could hear the tone on your multimeter. Keep up the great work. I was surprised on the great prices of your charger control boards. Thanks, Ted M.

[@mikedamico8833]

Great video! The single board replaces the dual board version that I have. I would have enjoyed seeing where the black wire (next to the red wire on the relay board) plugged in.

[@IsaacSells]

Me too

[@JC_MCC1923]

If the fuse and or diodes is bad will it make the board act as if it's bad too ... I touched the screw driver across the relay on my new board and it turned charger on..I

[@barrycrowe4629]

My PCB has several more connections than shown in your video. How do I identify what part number I need to purchase?

[@5literranger]

thanks so much for this. I found this video helpful and it lead me to a broken wire right at the relay.

[@mytexasdays1526]

Thank you 💓. Unusual but my ac power cord was bad and the capacitor as well. I'll check the rest when those two are installed.

[@mytexasdays1526]

I replaced the 50 amp use, power cord and capacitor 9.24.22. Unclear how to check the transformer. All else checked good as in the video. Plugged it in 9/25/22. Nothing. Zip. Screwdriver across the relay terminals and it arced. What do I do now?

[@user-tq9lb3pl9f]

Thank you for testing info. I had a spark when I touched terminals on relay, so is the board ok? I did not get a continuity sound when i checked the negative side of cart plug that goes into the cart. So, do you think the pug itself is bad? S. Mccoy

[@nusyil]

Great and very clear explanation!! Thanks a lot. But , better explain that, to turn the charger on, at least batteries must have 27V DC. Otherwise the charger won't be turned on!!

[@barbarae.9734]

Excellent video! I am an older lady and try to do my own repairs. There is no one in my neck of the woods that would know how to repair this. My charger is a “Total Charge”. I would like to know if the Powerwise is similar enough for me to follow your video and repair my charger? Please say yes so I can get this done! LOL Any other advice would be appreciated. Thank you kindly.

[@chriszbodula1894]

I can't thank you enough for your video. When I did my testing I went right to the relay and determined there was no power on the output side. I then asked myself if the DC plug needed to see a load for the relay to engage but your video answered that question for me. I will try jumping tomorrow then buy a replacement relay and swap them out.

[@jessaryenterprises]

Very good video!! You fixed my charger!!

[@mrcleanisin]

How does jumping the relay burn up the board?

[@Philmomon]

A capacitor is an open circuit. Without disconnecting it, you are measuring the resistance of one of the transformer windings. If you disconnect the wires, you will read infinite resistance across the capacitor which doesn't tell you much about the capacitor since a bad capacitor will often read infinite resistance as well. A lightning strike is about the only thing that will take one out so in most cases, as you said, the capacitor is rarely a problem. You will need a capacitor tester or a big series resistor and know something about time constants otherwise. Good video, Thanks.

[@ganeden553]

Well Greg Moore so nice of you to add your 82 cents to the DIY lesson. My question is....If you know all about all why are you subscribed to a Tutorial?

[@johnshea8675]

@@ganeden553 I definitely agree with your statement there. I always find it funny when people criticize other people on how what they are doing is wrong on a tutorial, which means you typed in the search a question as to how to do something. Why are you looking it up if you already know. why dont you channel showing people how to do it? I am at the point where every time i watch a tuturial and i see someone else telling them how they are doing it so wrong and the correct way to do it that I ask them why they are looking up "how to" videos in the first place. generally i get no response back.

[@verhillovalakay5393]

for a better test for capacitor disconnect those wires from transformer coil and put the tester in to capacitor mode if have or dischrge first the capacitor by shorting the two terminal

[@mr.foshow5474]

Hello thank you for showing this video I have followed all your guide it’s really good video the one thing you probably forgot to mention what if the capacitor is not giving you any reading and also when you had the screwdriver on both of the leads and it made a humming sound does that mean the board is bad or the board is good because when I touch the two leads that goes into the relay it made a humming sound is that mean the The board is good or the board is bad and I did not have any reading on the capacitors thanks in advance I’ll be looking forward to your reply back thanks

[@1fatcat65]

My new diodes still show continuity with the heat sink board? Any idea why?

[@MSmith6383]

Great video

[@johnnyg6448]

When I touched both terminals on the relay together it sparked like it shorted out or something. I assuming a bad transformer? When I plug in my charger on my golf cart it makes the humming noise but It wont charge it

[@mikee4216]

Thank you for posting this most helpful video. I have a used Power Wise charger model# 29115G04 with the single circuit board. I have tested it per this video and it needs a new board. The red ground clip wire from the DC plug has been cut off after the cord enters the charger. Where does this wire connect?

[@petecook1611]

I jumped my relay charger came on but tripped my outlet I'm assuming something in the board is bad??

[@user-co2wo7ej2f]

Outstanding video! Thank you for sharing your knowledge!

[@golfcartking]

Thank you

[@jimcook9617]

First, thank you for the video. Very helpful. Question I have: Was not seeing continuity from the ground bar in the charge plug to the screw connection in the charger, but was able to see continuity between the grounding bar to the red wire you unplugged. Should I move forward or is that an issue? One other thing: I think my capacitor was showing slightly more than 1.9 ohms (more like 2.9 - 3.2). Thanks in advance.

[@jameskracium1184]

Hey I like all your info. You u give out keep it up. If I just the 2 wires on the control board mine sound like a loud hum not seeing the meter on the front move is that normal.

[@denselgilpin6495]

all of a sudden when i plug it in the needle does not jump over to 6 or 8 but it seemms to be charging what could that be

[@jimjustus6779]

Have burnt wire off of capacitor. The years have taken a toll on the label of capacitor. What fared an voltage is the capacitor?

[@erniehurley497]

Wow great video thank you

[@aarteezee1]

Good video. My charger works fine, but the gauge never moves. Bad gauge ?

[@golfcartking]

Sounds like bad gauge, that's very common.

[@lynnwalker6818]

Thank you! Thank you! Thank you!

[@navarrojuleo1]

I did the test on the board and when I did the bridge on the two black wires it started charging but on the capacitor you said to get about 1.5 1.6 ohms and I only got 1. Could it be possible the capacitor is bad? Thanks

[@accordioneddie]

disconnect the cap measure across the two pins after shorting so you don't blow your meter!! then set on low ohms if no short , turn your meter to meg ohms measure again, if its good it will charge like a battery with your meter on ohms it supply's the power

[@inlandgroup]

I have changed the IC plate and the heat plate. Still not working. Something am missing to check. How much are the new ones.

[@hove131]

Bypassed the relay on a customer's charger and got it running. Soldered in a new relay. It's still not working. Any ideas?

[@ganeden553]

What is the small red wire lead from the charger board to the resistance cooling wall? Why is it plugged in to the resistance cooling wall? Does it need to make contact with the resistance cooling wall for the charger to maintain working condition?

[@jeremyankrom5151]

So if you plug the charger into 110 and plug it into the golf cart in the needle does not move on the charger at all I know that I'm getting 110 power because I plugged it in somewhere else

[@uknowjack]

Nice video. But I need help. I believe I have miss arranged up my D.C. wires coming into the charger. Can someone tell me what the black, green and white wires coming in hook up with? Also which one of these wires hocks up with the thin red one coming from the new board. Its been a summer headache for me.

[@garyharper4032]

Note : you have to have atleast 32 volts before charger will activate. My batteries are 4 years old and the charger doesn't work sometimes. I disconnect and charge 1 at a time till enough voltage is present.

[@nusyil]

Thanks a lot Sir!!. That was the answer my question that i had been looking for!!! One customer brought me this for repair. I faced first time off with this device and i realized that , there must be some voltage to start-up the circuit. So i tried, 14V, 20V, 24V at last, 27V the circuit board turned on and relay "click"ed. I knew it logic of to work the circuit, but i wasn't sure..Thanks to you, now i'm sure. Really thank you again Sir!! Have a great day!!!

[@garyharper4032]

@nusyil your welcome I'm glad the information helped.

[@Tctenor44]

I don’t know what I am doing but am pretty sure my capacitor read 2.1. My charger comes on but only goes to like 5 amps.

[@romancastillo9084]

Hey I have a similar charger can you help me fixed it for some cash

[@TheStrafendestroy]

My plug is only two prong not three so tested from the green ground with the screw and no sound. Is this the correct method to test the ground without having that third ground prong

[@derekrohlfsen467]

That was fantastic!

[@golfcartking]

Thanks for watching and don't forget to subscribe!!

[@mrn0782]

Very helpful video. I am a bit confused on testing the board; if the charger (transformer) kicks on when you touch the screwdriver to both terminals coming into the relay, does that mean the board is bad? Thanks!

[@golfcartking]

+mrn0782 Touching both terminals with the screwdriver is just a way to do a quick check to see if the transformer is good. By doing that, you're actually bypassing the board and forcing the charger to come on. If the batteries are too low, you can jump start the charger by doing this.

[@SailingKitabu]

Tested the diodes to heat sink, measure 0 ohms (full continuity) on both diodes, with test leads in either orientation. Fuse was also blown. Haven't tested board yet. Any thoughts? No output / no life from charger. All power cables continuity is good.

[@paulshepherd3878]

Great video! Helped me diagnose my charger.. my cart is a 36 v and it has 4 6 volt batteries and 2 8 volt batteries.. I bought it this way at a auction .. is that a big deal? Should i replace the 2 8 volt batteries?

[@golfcartking]

That could damage the controller and a 36 volt charger may not fully charge the batteries.

[@racerx757]

Awesome just what I needed thanks So much

[@alanproteau6849]

I replaced the board, diodes and fuse. I am getting continuity through the diodes to the aluminum panel even after replacing both of them. Any ideas would be most helpful.. Thanks! AL

[@kathleensalisbury2272]

Thank you so much for your awesome video! I replaced the diodes and the circuit board and it seems to be working!! There's another circuit board behind where the diodes are mounted. I noticed a resistor (200 ohm, I think) near the top of the board that looks brownish on the bottom. Or is it might be some kind of glue?? It reads much higher than 200 ohms. Should I replace it? Thanks so much!!

[@kathleensalisbury2272]

Please ignore my question. I was reading the color bands from the wrong direction. It is brown, black, red, and gold - a 1k resistor. I think the brown underneath is some sort of resin glue. All is well! Thanks again! :)

[@wallracing5]

I have a powerwise 2 charger that wont click or come on. I tried bypassing relay like ive done temporarily on regular powerwise charger before but it still didnt come on. Any suggestions?

[@teddysplace]

I have a ezgo total charger 3 that won’t charger do u have repair video

[@GARE0HIO]

I have a 2007 Ezgo battery operated cart. First off if the batteries 3.3 to 3.7 volts will the charger PowerWise 28115 G04 ) try and charge them? If the batteries are bad I have seen these chemicals that are supposed to bring the batteries back to life . Will they ? With out using the powerwise charger do i need to disconnect the batteries to charge with a standard 6 volt charger ? BTW THANKS IN ADVANCE I AM VERY IMPRESSED with your videos :)

[@golfcartking]

With the voltages being that low, the charger will not come on. As far getting the batteries charged you have a couple of options. (1) Disconnect each battery and charge it one at a time till it begins boiling. Reconnect the batteries and the charger should come on. (2) Using a set of jumper cables, hook across the battery pack with another golf cart so the charger will recognize more voltage. Once the charger come on, disconnect the jumper cables.

[@skinnyt72]

use a 12 volt charger on each battery for about 3-4 mins then hook up the ezgo charger...repet if needed

[@LanceDaigle]

OK, I ordered a circuit board. I currently have an old one with two boards. Can I get rid of the other board now? I see you plug the little red wire from the new board to spot on the wall. Where do I plug the little black wire coming off the board to? I'm guessing it plugs into the ground wire that is plugged into the other board but want to make sure I do it right. Thank you.

[@golfcartking]

Yes, this board replaces the 2 original boards. The front board will no longer be used and the one laying down will be replaced with your new board. The RED wire does got to the heat sink and the BLACK wire connects to the RED wire from the AC cord.

[@jamesnelson3616]

At 2:55 of the video, you disconnected two wires. Where does the wire in your right hand attach to? Also, is there a way to remove the board in front and if you do, where do you connect the wire?

[@mrhoya14]

So if the diodes are bad it doesnt charge? My circuit board is bad because if i tap both with a screwdriver it starts humming.. But if i touch the diode to the plate it reads a number, my multimeter doesnt have the beep sound so im am using the ohms to check continuity

[@vernonlewis630]

t has been working fine until I plugged it in and noticed that the meter only went half way and the charger was making a loud buzzing noise and getting really what do U think is my problem and what should I check first ? Thanks

[@joepirelli8688]

Hi I replaced the board in my 36 volt power wise charger, the one board replaced the two old boards but when I plug it into the golf cart it still will not come on, I unplugged the two black wires on the black box and connected them together and you could hear the transformer come on, I charged the golf cart like this so I figured this brand new board would fix the issue but it has not, any other diagnostic help would be greatly appreciated, thank you!

[@jerrypotter6463]

What would cause the 50amp fuse to blow?

[@madelinehildebrand9549]

I have narrowed it down to the relay being bad. If I do bypass the relay and charge the cart this way temporarily will the meter on the charger show any amps on the ammeter as it would if it were connected through the relay?

[@golfcartking]

Yes, it should

[@InventPeace1]

Can you tell me where I could get a QuiQ Delto Q 72v (yellow top, black sides) HF/PFC charger repaired, I checked Ac in - ok, can't find any dc anywhere in the system. I checked 2 what looked like slo-blow fuses, they seemed ok (no v either side of either one). Very perplexed, no lights at all ever; with ac plugged in, not even one led lights up? THANKS>

[@compoundwk-9rescuecorp791]

Barry, do you happen to know if a charger that is using diodes, can the diodes be replaced with the heat sink terminal that is used on this charger you are working on? thank you in advance, Dean

[@compoundwk-9rescuecorp791]

never mind LOL, i just replayed and saw you point out the new diodes are what i should be using :-)

[@lindasalazar9154]

Great presentation. Thanks for your help! Happy Halloween!

[@mrhoya14]

How many volts at the main terminals should my multimeter read while the charger is plugged in to the cart? 36v system

[@Smith_jeff]

I’ve replaced the control board on my powerwise charger and it keeps blowing fuses and will not charge my golf cart. Why is this happening? Thank you for any help.

[@golfcartking]

Sounds more like a transformer issue.

[@Smith_jeff]

Diodes were bad I had continuity between the board and the diodes

[@Smith_jeff]

How do you replace the diodes?

[@golfcartking]

@@Smith_jeff www.golfcartking.com/ezgo-stud-type-diode-2010/ The new ones you dill a hole and mount them

[@breeze787]

Thumbs way up. Thanks for sharing that.

[@curry3185]

Thanks, most helpfull

[@Cweinig]

Replaced relay board. Relay doesn’t seal, turns on and off. Why?

[@DubRussell77]

Barry, Is there a way I can contact you directly? Thank you for the video.

[@bobseifried8516]

What would cause the fuse to blow

[@InventPeace1]

Or where to get a lower cost plain jane amp meter type that auto shuts off when 72v lead acid pack is charged ? thanks

[@awademan]

What size capacitor is used in this charger?

[@bobgarcia4343]

I followed the test procedure up until the diode segment. I was getting continuity from diode to aluminum plate/heat sink so I ordered new diodes . Still get continuity with the new diodes. Am I doing something wrong?

[@bobgarcia4343]

@Barry Wilson So, it seems like continuity issue is fixed . Long story short, my dad had put in the new diodes we ordered and still got continuity, so he put the old diodes back in (The ones attached to the small board) and they fixed themselves somehow. We will continue with diagnosis now. Sorry to bother you .

[@noahrhoades1893]

Any ideas for diagnosing a charger that wont kick off whenever the cart is fully charged? Also the charger will hum when plugged only into the wall

[@barrywilson6665]

That sounds like either a bad timer board or a weak battery not accepting a full charge.

[@Lil_dirtbikemike]

I need help *** I've replaced my board and fuse twice.. no luck. However my cart charges with the male jumper I have made. Any ideas ? It is possible I have gotten two bad boards ?

[@golfcartking]

Sounds like the charger may have an intermittent short within the coil of the transformer. I see a new charger in your future.

[@Lil_dirtbikemike]

thanks

[@lisagarfinkel3009]

I have a 2009 Gold Std Prec Elec 2 plus 2. The batteries are not holding a charge, Club Cart service recommended upgrading on-board computer to version 5.5 or 6 and replacing all of the batteries. Is this the most up to date version, I have 4, 12 volt batteries. Will this solve my problem?

[@golfcartking]

Lisa Garfinkel Unless your OBC (on-board computer) is bad (not functioning) I wouldn't replace it. Just because they may have made some changes, for me doesn't justify spending that much money. Changing batteries may help because the 12 Volt batteries were never that good of a battery. Give me a call and I'll tell you how to correctly check your batteries. (Load Test)

[@Highball28]

I watched this video charger is good. When I plug the charger in it will run for about 45 mins. and then turns off. The battery's are brand new. I have a 97 Ez-Go TXT 36 volt cart I also installed the large cables. I'm at a loss for what to look for. Thanks James

[@golfcartking]

James High What's the problem? Are the batteries not getting fully charged? Load test the batteries "Brand New" realistically means nothing. I've gotten bad batteries right from the battery store.

[@Highball28]

Load tested . Battery's maintain 6.7 volts ea. after load testing. Cart stops after riding though the park after about 1 hour or so. The charger turning off makes me think it's not fully charging .I have the older powerwise charger with the 2 boards diodes tested fine.The relay clicks . So I don't want to install a board and this not be the issue . Thanks

[@golfcartking]

James High When it's time to charge your golf car, put your multimeter (set on VDC) across the battery pack and clip it to the terminals so that it will stay in place. Once the voltage settles, plug the charger in and watch the voltage increase. Make sure it goes up to around 41 to 43 volts.

[@Highball28]

Borrowed another charger . It worked so I know now it's the charger. Thanks Much.

[@mikepatterson]

+DIY Golf Cart Hey DIY, when my charger charges my golf cart, it takes the batteries up to 46.3V. Isn't that too high? I can smell the batteries gassing.

[@user-co2wo7ej2f]

Hey DIY Guys.... Your Control Boards are out of stock! Your video lessons must be working. Keep up the good work.

[@uknowjack]

When i do the heat sink diode test my multi meter does not beep but gives a reading of 546 on each one, is that normal? Thank you

[@golfcartking]

Are you checking continuity in both directions?

[@dennisgarrett263]

Is capacitor 1.1 to weak???

[@LANDSURVEYER]

?? The charger hums as soon as it is plunged in. Is my relay on the board bad??

[@shadsheldon2429]

Charger only runs 30 minutes and shuts off on both my golf carts..... usually runs 4-5 hours. Whats the problem?

[@ckacka2]

Thank you so much!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!