F&R Switch Question

konakid

I've got a 36v EZGO (I'm guessing about a 2001). I've had an intermittent problem of it just cutting out - almost all the way - but then working again after turning off and on, forward/reverse, rolling a little, or just waiting.

It's been very hard to diagnose, because it is infrequent - and because I know about a "2" on a "1-10" scale about these things. I've changed out a few things - micro-switch, solenoid, diode - and then I bought new batteries, cleaned cables very well, etc. After that, it worked great - I thought I had fixed it. Now after a week, it did it again. But after a few minutes of turning the key, etc. it is working again.

So - it looks like I'm looking at a controller, or motor brushes. But, before I go that route - which may mean just junking it - I have this question.

It has a rocker switch on the dash for forward and reverse. Is this custom? Could my problem be just a bad F&R switch? How do these "electric" switches work as opposed to the "lever" kind. In other words - is this worth checking before considering the worst case scenario?

BGW

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konakid

OK - I've been reading some old topics, and answering some of my own questions. I guess I have a Sepex PDS setup - nothing custom.

And I guess the click I hear when I put the switch to F or N or R is the actual F/R switch making noise - and not the solenoid. Is that correct?

So, if you were me - what would you do the next time this happens. While it is "stalled," should I flip the F/R switch and listen for the clicks. If it clicks, but still doesn't run, I guess the problem is somewhere else.

I also guess that I should be hearing the solenoid click when I press the pedal. I always assumed the F/R click I heard was the solenoid - live and learn.

So, if the next time it "stalls" and I hear the click when switching between F + R - but it still doesn't run, and I don't hear the solenoid - then I will have a good clue correct? And if I do hear the solenoid click (but it still doesn't move) then I will have another different good clue - correct?

Am I making any sense? Anything else I should try doing or observing when this pesky problem is active?

JohnnieB

If I understand this correctly, the cart runs slowly rather than stopping completely and if you just let it sit for a few minutes, it run normally again.

That sounds like the controller is overheating.

Put the controller in diagnostic mode and drive it while in that mode.
When it misbehaves, listen for the beep code. (2-3 is for thermal cutback)

Attached is the PDS label and the text at the bottom tells you how to put controller in diagnostic mode.

Attached Images

PDS Label on Controller Cover.JPG (142.9 KB, 0 views)

konakid

Thanks JB - I'll give that a try.

But, i don't think that is it, because last time it "stalled" it was only about 30 seconds after taking off first thing in the morning. So not enough time to get hot. And it will start running again in 10-15 seconds of "playing around" with things. Not enough time to cool down.

And it isn't a complete shut down - there is still some life - but not much - and I don't want to sound too sure, but it almost "feels" as if there is a bad connection somewhere. But I can't seem to make it do it, even on bumpy ground.

If you were me, and it did this - what would be the first thing you would do or try narrow it down - realizing you might not have too much time before it just started working correctly again?

Would you try turning the key off and on to see if that made a difference? Or flipping the F/R, and trying again? Or "pumping" the pedal? Or just pushing it a few feet? Etc???

It happens rarely, so I wanted to take quick advantage when it happens. And I'm driving it a lot less now since I have a newer cart. I only want to get this sound so I can sell it.

konakid

Some additional info

I put switch to Run, key to off, toggled dash F/R switch to 'off' five times - no sound to confirm diagnostic mode. But there has never been a reverse sound either - since I bought this used.

I hear what I assume is the solenoid when I flip switch to F or R. Then after about 5 seconds, I hear what sounds like it flipping off. And if I depress pedal, it clicks again and moves. Is this how it is supposed to function?

scottyb

Yes, this is typical

konakid

OK - so I guess I can't use the diagnostic mode. Any other tips/tricks to perform next time this thing acts up?

timmyjane

If the reverse buzzer has been removed perhaps you should get one and then can use the onboard diagnostics mode. If the buzzer is too loud you can put a piece of duct tape over the buzzer output and it'll quiet it down significantly.

konakid

I'm getting a little more confused while trying to straighten this problem out. I thought I had a Sepex PDS since I have the F/R switch on the dash. But apparently then, this is supposed to have regen braking.

All I know is that there is no braking of any kind when going downhill. It is as if it was totally "free-wheeling."

I'm asking because I may have to replace the controller to fix this problem - but I have no idea which one to get. I would like to get the least expensive one available, as I wish to sell this cart - if I can solve this tricky issue.

JohnnieB

Whether iit has regen braking or not depends on what jumpers are connected on the plug the is plugged into J2. See attached.

Attached Images

	PDS Mode speed-regen level.JPG (18.5 KB, 0 views)
	PDS J2 mode plugs.jpg (130.2 KB, 0 views)