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Old 11-06-2015, 08:10 AM   #1
1arunem
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Default 1998 EZGO 'clicks' when pedal depressed

Hi guys.. new to the forum and hoping you can help. I have a 1998 ezgo electric (36v) and it has been at the lake unused for bout 3 months. I went today to pick it up and bring it home for the winter. I drove it from the back of the house to the front. I then backed it halfway up the tilt trailer when it stopped 'pulling'..

When I press the accelerator, I just hear a 'clicking'.. It seems to be coming from the rectangular vertically mounted box on the passenger side outboard of the batteries.. It has a plastic cover over it. I got home too late to do much but am wondering if you have any suggestions

Is the 'controller' under the plastic cover?

Like I said, it is not engaging the motor, I just hear a click whenever I press the pedal. I also smelled a pretty strong 'burn' odor... Is there a way to diagnose the issue?

Thanks in advance!

Warren..
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Old 11-06-2015, 08:41 AM   #2
mgray70
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That is where the controller is located. Remove the four bolts that hold the cover on. If it is burnt as bad as you say the smell is there may be some melting on the controller. If not follow the troubleshooting guide in the stickies for the controller. My guess is its toast. Mine did the same thing while loading on a trailer.
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Old 11-06-2015, 08:45 AM   #3
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Default Re: 1998 EZGO 'clicks' when pedal depressed

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Originally Posted by 1arunem View Post
Hi guys.. new to the forum and hoping you can help. I have a 1998 ezgo electric (36v) and it has been at the lake unused for bout 3 months.
i would charge it before anything else
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Old 11-06-2015, 08:46 AM   #4
scottyb
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Default Re: 1998 EZGO 'clicks' when pedal depressed

Classic low battery controller failure. When the batteries are low in voltage the motor draws additional amperage to make the motor run. (volts + amps = watts or motor operation) The excess amperage drawn causes the controller to fail.

My guess is there may be a run/maintenance switch on the controller cover? We need to know this.
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Old 11-06-2015, 08:55 AM   #5
1arunem
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Default Re: 1998 EZGO 'clicks' when pedal depressed

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Originally Posted by scottyb View Post
Classic low battery controller failure. When the batteries are low in voltage the motor draws additional amperage to make the motor run. (volts + amps = watts or motor operation) The excess amperage drawn causes the controller to fail.

My guess is there may be a run/maintenance switch on the controller cover? We need to know this.
This was my initial thinking as well.. Felt it may have over amped/heated the controller and fried it.

I did not see any 'switch' on the cover. I will remove it this weekend and have a look at the controller.

As far as the batteries, I put them on the charge when I got home and they seemed low (per the charger gauge) but not stone dead.

Thanks for any additional insight!
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Old 11-06-2015, 08:59 AM   #6
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Default Re: 1998 EZGO 'clicks' when pedal depressed

Te maintenance switch is on the outside of the cover... these carts were especially susceptible to this meltdown scenario although it can happen with any control. Lead acid batteries have a self discharge rate of 1% per day. so after 3 months they were 90% depleted. This is well below the 50% acceptable level.
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Old 11-08-2015, 11:50 AM   #7
1arunem
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Default Re: 1998 EZGO 'clicks' when pedal depressed

Ok, I have taken the cover off and see the solenoid and what I presume is the controller..


The solenoid has two large posts (one on either side) and two small ones in the middle (one with red wires, other black).

There is no 'switch' on the cover..

Can anyone point me to a link or tell me how to check power etc with a voltmeter coming in/out of the solenoid, etc.?

Thanks in advance..
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Old 11-08-2015, 02:24 PM   #8
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Default Re: 1998 EZGO 'clicks' when pedal depressed

OK, did a little poking around..

With key on I am getting 37.7 volts at the battery side of the solenoid. I am getting 23.9 volts on the other side..

Per the diagnostic it indicates the resistor may be bad. Where is the resistor?


Thoughts?
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Old 11-08-2015, 02:44 PM   #9
JohnnieB
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Default Re: 1998 EZGO 'clicks' when pedal depressed

The resistor is connected between the two large terminals on the solenoid.

The cart will run whether the resistor is good or bad, or removed. (Its purpose is to reducing arcing on the solenoid contacts, prolonging their life.)

When the solenoid is energized (contacts closed), the voltage on both large terminals should be identical. If not, the solenoid is bad.
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Old 11-08-2015, 02:48 PM   #10
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Quote:
Originally Posted by 1arunem View Post
OK, did a little poking around..



With key on I am getting 37.7 volts at the battery side of the solenoid. I am getting 23.9 volts on the other side..



Per the diagnostic it indicates the resistor may be bad. Where is the resistor?





Thoughts?

The resistor is located between the large posts of the solenoid. It would not cause the cart to stop. Does the solenoid click when the pedal is pressed? If so what are the voltage on both side of the solenoid while it is engaged?
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