Medalist non-dcs troubleshooting

Dtidwell05

Hello guys, I recently bought a 1994 E-Z-Go Medalist 36v cart. It has a brand new set of batteries in it and it doesn't go.... Foreword or reverse. Here is the troubleshooting I have done so far.... Solenoid clicks when pedal pressed. Solenoid does not have a resistor between the 2 bigger lugs. It does have a diode between the 2 small lugs. When I check voltage across the 2 large lugs on the solenoid it reads 6.3 volts on the battery side and 6.1 volts on the other side, so I know there is a problem there. Next I put the ground on the M- terminal and the positive on the B+ terminal on the controller. Reading is at 6.1 volts without depressing accelerator and goes to full voltage when pressed. 38.6 volts. Next I moved to the directional switch. It is getting the same voltage as B+ At the bottom lug, but when in foreword or reverse the power does not go to either lug on the direction switch. The top lug on the direction switch (A2) gives me a .7 ohm reading when I put the meter on it. My first instinct tells me it's the direction switch is my problem, but I am confused why foreword and reverse are out. The direction switch appears to be in good shape. Reverse buzzer works when switched that way. I am just curious if I am on the right track?

BGW

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scottyb

Welcome to BGW - see below
Download, print, report results at all 7 steps. You'll be running in no time.

Attached Files

DCS testing procedures.pdf (81.2 KB, 0 views)

Dtidwell05

Thank you! My cart is the non-Dcs system or the "series" system maybe. Has a actual lever for foreword and reverse, and does not have a tow/maintenance switch. I will try to link some photobucket images of my system.

Dtidwell05

I can't post links since I am a new member.

scottyb

My bad. non DCS is a term they never should have printed. All carts were series until DCS so why DCS and non DCS? Later they introduced PDS so then non DCS became a useless designation. We have Series, DCS, PDS, and a few more today from Ezgo.
So from now on you have a series drive cart. See flow chart below

Attached Images

ezgo-guide-#2.jpg (139.0 KB, 0 views)

Dtidwell05

Here is my main question right now..... Since the foreword/reverse switch is a mechanical lever style switch, shouldn't the voltage go from the input post to the output post when switched regardless of anything else? I can put my volt meter on the input post coming from the controller and the voltage matches the controller, but the voltage does not make the jump to the foreword or reverse post. I am confused what the 4th post is for? It ties into the A2 on the motor and controller.

Dtidwell05

I see. Series drive for sure!

scottyb

Does the solenoid click when you try to go? If no print this diagram and check for 38v at the beginning and end of each red line starting at the charge receptacle.

Attached Images

Ezgo Series solenoid activation diagram.jpg (107.9 KB, 0 views)

Dtidwell05

Yes solenoid does click.

scottyb

Solenoid clicks. You should have a throttle signal. See test attached(series and non-series same reading on this test)

Attached Images

DCS ITS.jpg (225.4 KB, 0 views)