95 ezgo question

ncseadad

Hello my golf cart buddies....Raining here in NC so it gives me time to ask a couple questions..

My personal GC is a 95 ezgo series non DCS 36 volt. I live near the beach and the frame broke in half. I found another frame and transferred everything from the old one to the new one. Keep in mind the old one ran great.

Well, I reworked the frame and all parts. I clean, painted or replaced parts that needed it.

Back together, the cart moved in both directions, however forward was half speed and reverse was full speed. So I reversed the 3 and 9 wire on the F/R switch. Now its fast going forward but the handle is in reverse, same with reverse. No motor wires were taken off during swap over and I thought I marked wires on F/R switch..

My second question:..I really don't mind putting the handle in reverse to go forward...my wife don't like it...lol...The other thing is at times when you start off it goes slow, like half throttle and then all of a sudden it will kick in and run like it should. I have a built in voltmeter and the volt drop is the same whether its going slow or fast. It feels like you are going from half battery pack to full battery pack, but voltmeter says it stays the same...no volt drop or increase when it does all of a sudden pick up...Once going at normal speed, it does not slow down like in a speed sensor. (which this cart does not have).. Just not sure where to look for this problem...

Thanks guys.

BGW

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scottyb

Check out this instruction from the Ezgo manual edited for my switch cam install. Compare your F&R linkage attachment bracket to the position of the bracket in the instruction. If you have either linkage bracket up side down the lever action will be reversed. Maybe that's the situation?

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JohnnieB

Something is strange. Half speed occurs when MS4 on the F/R assembly puts 36V on the orange wire (Pin-3 on the controller) which is independent of which direction the cart goes. If the cart is going forward with the F/R selector in Reverse, MS-4 ought to be putting voltage on Pin-3 and the controller ought to be in half-speed mode.

It sounds like MS-4 isn't synced with the position of the F/R lever.

I've never seen a F/R assembly, so I'm not sure how the lever and switches can get out of sync or if it is possible to install it upside down, but something isn't right.

However, try putting the cables at 3 and 9 on the F/R back where they were and reverse the A1 and A2 cables on the motor.


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I see Scotty posted the explanation. Lever upside down on the linkage. Correct the linkage and put the cables on 3 & 9 back in their original position and it should be going full speed froward and half speed reverse.

ncseadad

OK...both of you may be talking about the same thing or at least in the same area...So, you are suggest to turn the back side of the F/R switch around...I think Z in the diagram. OK...that makes since. I put a new F/R switch on during the rebuild. I don't like removing the motor wires because it is so easy to break the contacts from the studs inside the motor, so no motor wires were removed. I will turn the back plate upside down and switch the F/R 3 and 9 wires and will get back to you...

Hey also, speaking of F/R switch. a little something I ran across while doing this rebuild..New F/R switch would not go but one direction to start...check, check and rechecked everything...Come to find out one of the brass contacts were out of line just so slightly. Had to look hard to see it, but was riding on the rim or edge of the other brass block and was not making contact....Just saying..

ncseadad

Scotty...my mistake...you suggest to check linkage not reverse the back part...ok sorry...just that I thought about switching the back part and just read to fast into your message...Not sure how the linkage being hooked wrong would matter but you are the man....
I will check the linkage and get back...

ncseadad

Hey guys, this is a partial update...It has been raining so much here on the coast of NC that its been hard to get in my yard for the past month. I did however change back the 3 and 9 wires one the F/R switch. ( like it should be). Now it goes forward when in forward and visa versa...I tried it like that and it still runs about half throttle. I did notice I only have about half voltage on the controller side of the solenoid. It started raining on me AGAIN so didn't get a chance to put A1 and A2 back in their correct positions...I will repost as soon as the two are switched back and tried...Welcome to put input in the mean time...Thanks

JohnnieB

When the solenoid is energized (contacts closed), you should have FULL battery pack voltage on the controller side large terminal no matter if F/R is in F or R.

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Dopes the beeper work?
If so, the same microswitch on the F/R assembly that makes the beeper sound, also puts the controller in half speed.

ncseadad

OK JohnnieB. To answer your question first about the solenoid...The cart does not have any resisters/diodes on solenoid. After cart sits for a while the controller side of the solenoid will drop to 0. Now Just as solenoid clicks it has pack voltage, but when you release the peddle as the solenoid clicks again the volts starts dropping back to 0. The volts when the solenoid clicks is the exact same on both sides of the solenoid..

Now, as I stated in the previous message I switched 3 and 9. and the cart went forward when the F/R switch was in forward...but still runs 1/2 power in forward and reverse

Now that I have switched back A1 and A2 the cart goes reverse when the F/R switch is in Forward and visa versa. and still runs 1/2 power in forward or reverse.

The solenoid still acts the same with A1 and A2 switched...solenoid clicks has exact volts on both sides of solenoid....and then drops to 0 after a while...

I hope this helps....I

ncseadad

JohnnieB...the only other thing I can think of to tell you is that on one of the test where you touch the +probe to the with wire on 6 pin connector at controller, you are suppose to have I think .45 to .55 volts...when micro switch first clicks. well I have .49 before it clicks....

The other thing.;; I have a volt meter on my cart and through all the test of switching wires back and forth when the peddle is all the way to the floor the volts don't drop a lot maybe 1 to 1/2 volts...

JohnnieB

Direction cart goes with respect to position F/R lever is in, is one problem and going at 1/2 speed in both directions is a separate issue.

Get the cart direction and lever position (and when buzzer sounds) sorted out and then we can troubleshoot the 1/2 speed issue.