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Unread 08-11-2016, 04:20 PM   #11
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Default Re: Big Daddy's rebuild- couple questions along the way

Awesome, much appreciated. Thank you, looks like I have some reading to do.
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Unread 08-15-2016, 07:22 AM   #12
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Default Re: Big Daddy's rebuild- couple questions along the way

I was hoping to have the materials to build some new cables over the weekend, but no such luck. So I took it easy, listened to the rain beat on the bard roof, and just enjoyed some light work.

Got the "auxilliary" wiring removed. Wow, what a hacked up mess. Still have a bit more clean up to do, but its a lot better. I also picked up an aux battery for the 12v lights and radio, I have a trickle charger left over from my motorcycle days, so I think this will work out nice.

Couple other clean up, and trouble shooting items I did: There were no bolts on the sides where the canopy had been, corrected that. also, I had been jumping the solenoid to get the cart to go (for "tests", lol).

I'm a fair trouble shooter (15+ years as commercial HVAC tech) but I have to say, why in the WORLD did EZ GO decide to power the control circuit thru the charger circuit (reed switch) and also WHY did they put that spade connection on the reed switch pigtail??? Its seems a magnet for corrosion and failure (obviously, this was my issue), a dirty 14g spade terminal, kept the cart from running properly.

I will say this, the troubleshooting flow chart makes this diagnosis so easy, well, even a caveman can do it! Many thanks to the folks on here for getting that to me, much appreciated. I would have likely eventually found the issue, but I was "figuring" since the wiring diagram does not show, that the control circuit was fed off orange from the controller. Figured wrong, lol!

So, lots more to do. Took one last ride with the 12 volter in the pack (new battery this weekend!) prepping by removing all the batteries, doing a thorough clean, replace, tie up, and generally clean up the wiring and cables.

Also plan a general hose down, wipe off, etc of the cart. This winter will be the paint and body.

So, here is what we will call the "before". This is after 2-4 hours of removing the wiring for lights and radio (junk wiring) troubleshooting, a minimal clean up, and with the test run 12 volt battery in the pack.

You can see a bit of my 2 best helpers, my 9 year old (as of Sunday) Eldest son, and my 6 year old middle son. The 4 year old is a rider, but not much of a helper. LOL. My 2 girls are almost too old to hang out with pops anymore, 11 and 13.

20160814_151733_resized.jpg
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Unread 08-15-2016, 07:38 AM   #13
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Default Re: Big Daddy's rebuild- couple questions along the way

Looking good Pops. Before you plunge into buying a new set of batteries read up on 48v operation. 6/8v batteries drop right in the battery tray. All the upgraded controllers and F&R switches handle the 48v and the stock motor produces 33% more speed and torque on 48v... I know, your thinking that would be nice for me but what about the kids? Don't want them having too much speed and power? Install the FN shift on the fly selector in a hidden location and turn it down when the kids are using it..... works great for the wife too.
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Unread 08-15-2016, 08:48 AM   #14
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Default Re: Big Daddy's rebuild- couple questions along the way

I have been thinking about doing an upgrade, but cash is a bit tight (5 kids, remember, lol).

What I have determined for sure is this: I want this thing to stay useful as a utility vehicle around the property. Range of operation is a higher priority than speed.

I was thinking of a very small lift with stock size tires (rural king also carries a small atv tire for 8" rims) just to make the on and off a bit easier and set it apart a bit from completely stock.

So, I looked at your page, and its quite impressive. Lots of good info, a bit overwhelming for a newbie like myself. I have been thinking going 42v this winter with the "complete rebuild". Will the stock components handle this long term? Will my range increase?

I am going to be installing a pair of previously used 6 volters since my other 4 batteries are in good shape for now, and just over a year old. 8 volt is not out of the realm of possibility for the beginning of performance upgrades. If that is the best option, then just tell me, I am all ears, and you really, obviously are very knowledgeable.

Lastly, I will only go with the ATV tires if this thing will go in the snow some. Now, I am not talking 6" snow, but a few inches? I have had it out "testing" and we have a muddy sloppy mess right now, and it does just fine, but snow is a different beast all together.
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Unread 08-15-2016, 12:12 PM   #15
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Default Re: Big Daddy's rebuild- couple questions along the way

To understand the What and the Why of some of the things EZGO did, you have to think in lawyer and accountant modes as well as being an engineer or technician. Wearing a tinfoil hat also helps.

A magnet in the charger's DC output plug opens the reed switch, disabling the car so it cannot be driven away with the charger plugged into it. Reed switch failures occurred out in the middle of nowhere so many times that EZGO stopped installing them in about 2007 and went with an electronic circuit that disabled the cart when they came out with the more recent 48V systems. With the newer 48V systems, you have to replace the entire charge receptacle instead of just the reed switch, but both types can be bypassed by connecting the wire the feeds the control circuit to B+.

The in-line connectors make the carts easier to assemble at the factory, but cause problems in the field.

You may have also noticed that the NC contacts of the microswitches are used, so cart operation depends several itty-bitty springs that close the microswitches' NC contacts when their levers are released.

You may or may not have noticed that many of the battery chargers being used sense the battery pack voltage via an auxiliary contact in the chargers plug. It senses B- by touching the outside of the negative radsok in the cart's charger receptacle and B+ is sensed by a wire attached to the heatsink inside the charger. Basically 1/2 of a Kelvin (4-wire) measuring system that does very little except causing problems.

-----------
Range is based on how many kWh of energy is stored in the battery pack.
For the maximum driving distance on a single charge go with an 8 x 6V 48V battery pack using the highest AH 6V batteries available.

The next best is a 7 x 6V 42V battery pack. Not as much range (7/8 as much to be exact), but all seven batteries will fit under the seat without relocating stuff. I got over 30 miles of range using 7 Exide GC-145 (245AH - 6V) batteries from Rural King.

-----------

Be careful selecting tires, especially the ATV types. The low pressure ones (>15 PSI max inflation pressure) tend to be amp hogs and reduce range as well as top speed.

FWIW: My turf tires (Carlisle Turf Masters) do okay in snow deep enough for the differential to plow a furrow. Climbed a 15 incline to jump start a car.

Also be aware that lifting the cart's frame and body off the axles does not increase ground clearance at the differential, but it does reduce latitudinal and longitudinal stability of an already narrow tracked short wheel based vehicle.

You get 1/2" more ground clearance at the differential for each 1" taller tire height, while losing about 5% of the available torque were rubber meets road for each inch increase in tire height.

------------
Just about everything you do to a cart to make it usable for something other than chasing balls around on a golf course ends up being a compromise to some extent, so spend some time discovering the pluses and minuses and plan ahead before buying stuff.
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Unread 08-15-2016, 02:04 PM   #16
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Default Re: Big Daddy's rebuild- couple questions along the way

Quote:
Originally Posted by JohnnieB View Post
To understand the What and the Why of some of the things EZGO did, you have to think in lawyer and accountant modes as well as being an engineer or technician. Wearing a tinfoil hat also helps.

A magnet in the charger's DC output plug opens the reed switch, disabling the car so it cannot be driven away with the charger plugged into it. Reed switch failures occurred out in the middle of nowhere so many times that EZGO stopped installing them in about 2007 and went with an electronic circuit that disabled the cart when they came out with the more recent 48V systems. With the newer 48V systems, you have to replace the entire charge receptacle instead of just the reed switch, but both types can be bypassed by connecting the wire the feeds the control circuit to B+.

The in-line connectors make the carts easier to assemble at the factory, but cause problems in the field.

You may have also noticed that the NC contacts of the microswitches are used, so cart operation depends several itty-bitty springs that close the microswitches' NC contacts when their levers are released.

You may or may not have noticed that many of the battery chargers being used sense the battery pack voltage via an auxiliary contact in the chargers plug. It senses B- by touching the outside of the negative radsok in the cart's charger receptacle and B+ is sensed by a wire attached to the heatsink inside the charger. Basically 1/2 of a Kelvin (4-wire) measuring system that does very little except causing problems.

-----------
Range is based on how many kWh of energy is stored in the battery pack.
For the maximum driving distance on a single charge go with an 8 x 6V 48V battery pack using the highest AH 6V batteries available.

The next best is a 7 x 6V 42V battery pack. Not as much range (7/8 as much to be exact), but all seven batteries will fit under the seat without relocating stuff. I got over 30 miles of range using 7 Exide GC-145 (245AH - 6V) batteries from Rural King.

-----------

Be careful selecting tires, especially the ATV types. The low pressure ones (>15 PSI max inflation pressure) tend to be amp hogs and reduce range as well as top speed.

FWIW: My turf tires (Carlisle Turf Masters) do okay in snow deep enough for the differential to plow a furrow. Climbed a 15 incline to jump start a car.

Also be aware that lifting the cart's frame and body off the axles does not increase ground clearance at the differential, but it does reduce latitudinal and longitudinal stability of an already narrow tracked short wheel based vehicle.

You get 1/2" more ground clearance at the differential for each 1" taller tire height, while losing about 5% of the available torque were rubber meets road for each inch increase in tire height.

------------
Just about everything you do to a cart to make it usable for something other than chasing balls around on a golf course ends up being a compromise to some extent, so spend some time discovering the pluses and minuses and plan ahead before buying stuff.

Always great info JohnnieB, much appreciated! so, I take it you are a foil hat wearing lawyer? lol!

I understand the safety thing. I work for a very large OEM in the HVAC field, so I get that I guess. I was unaware of the charger deal, that is a great heads up, thank you.

I will be using the Rural kings as they are close and cheap enough. Do I have to upgrade my controller going 42v? Solenoid?

I'll likely stick to the stock tires and probably no lift. i was thinking the same thing about the "flotation" tires. I bet they eat batteries. You see a ton of lifted carts, and they look cool, but I really don't want to drop thousands of dollars on a toy that the kids play with. Just a toy for them, and a tool to make my life easier I hope.
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Unread 08-15-2016, 02:21 PM   #17
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Default Re: Big Daddy's rebuild- couple questions along the way

Thanks on the snow info as well. I'll keep that info to myself, else I'll never be able to tear it down, lol.
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Unread 08-19-2016, 10:45 PM   #18
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Default Re: Big Daddy's rebuild- couple questions along the way

Quote:
Originally Posted by BigDaddyChopShop View Post
I will say this, the troubleshooting flow chart makes this diagnosis so easy, well, even a caveman can do it! Many thanks to the folks on here for getting that to me, much appreciated.

Attachment 140243
Can you point me in the direction of "the troubleshooting flow chart"?
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Unread 08-22-2016, 09:44 AM   #19
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Default Re: Big Daddy's rebuild- couple questions along the way

it is the factory service manual. If you have a DVOM, you too can be an ace troubleshooter, lol. Link is in the stickies.
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Unread 08-22-2016, 09:49 AM   #20
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Default Re: Big Daddy's rebuild- couple questions along the way

Finally made some progress this weekend. Rural king had a killer sale on batteries, Regularly $79, got them for $62 each! Saweet!

For the mean time, I got 2 (yeah, I know, I know), and built some new cables (2 gauge) marine ends, shrink tube with adhesive, and away I went. Took a few hours. Also installed a new digital voltmeter (with numbers!) to monitor the batteries state of charge. My boys helped (ages 9, 6 and 5) and thought the heat shrink was magic! LOL. They were also quite impressed with dads stregnth on the crimping tool. It was a blast. My younger daughter (11) and youngest son also assisted with a bit of clean up. Putted around a bit, and put it on the charger overnight. Performance was vastly better already. More to come, if I can get them off it!

20160821_152633_resized.jpg
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