'05 EZ GO "no go" multiple issues I think

Txriverrat

I just picked up a '05 36v EZ Go that won't drive. This is my first cart and after quite a bit of research and troubleshooting I think I may have a few issues.

It's obviously been ran hard because some of the battery terminals are literally melted off and they screwed the rings to whats left of the lead. I cleaned all the terminals and made them as secure as possible just for testing. I have 35.3v at the pack and that goes up to over 38v when the charger is plugged in.

I've tested the solenoid and it tests good and I replaced the Curtis Sepex controller because the original stunk of burnt electronics and the case was warped due to overheating, however that made no difference with the new controller.

Issues:

First, the charger is a "smart charger" which I think has issues. When plugged into the cart it flashes the bottom light on the charger which is the fault light and that's whether or not the charger is plugged into AC voltage. When plugged into AC voltage the fault light and the light above it which is the "on" light both flash slowly. The charger will stay in this state for less than 10 minutes then it will trip the breaker to whatever circuit it's plugged into in the house.

Second, both speed controllers have a yellow (orange??) light that flashes about every 5 second when the key is on.

Third, accessories don't have voltage. You can feel the voltage reducer click when activated, but nothing comes on.

Fourth, I've seen during my research the "run/maintenance" switch. If I understand correctly, my cart should have this and it don't. The cover that was over my controller had a hole in it that someone sealed so maybe they removed the switch?? Is it necessary?

Troubleshooting I've done:
--I took (3) 12v deep cycle batteries from my boat and wired them in series and tested the cart off them and there was no change.
--I've tested the solenoid and it opens and closes as it should
--I've replaced the controller, no change
--I haven't found any fuses to check
--I've traced all of the wires as well as I can and can't see anything obvious

BGW

__________________
This advertising will not be shown in this way to registered members.
Register your free account today and become a member on Buggies Gone Wild Golf Cart Forum

orangeman6

Wow! It sounds like you've got quite the project on your hands. One good thing: this is one of the most helpful forums you will come across. There are a bunch of really knowledgeable guys that are more than willing to help.

I'm pretty much a novice here, but it sounds like you've got some serious issues with that drive system of this cart. But, if you're willing to spend a bit of $, are somewhat handy, and listen to what you learn here, you can get that thing going for sure.

Start by using the link below to ID the drive system. There are differences in the systems and how you'll proceed to check things.

http://www.buggiesgonewild.com/elect...en-system.html

orangeman6

You said the pack was at 35.3v. That's less than 30% on some packs, which I don't think is enough to get the cart to do anything. Even if it is, you also said that the cables/posts are melted and screwed together. You're going to have to fix the power problem before you're able to figure out what all is wrong. You did say you hooked up 3 12v to it? We're those batteries fully charged, and were the cables in good shape?

Maybe post some pictures of what you're working with.

Txriverrat

It is the Sepex system as I understand that page. It does have the F/R switch in the dash. Sorry, I had already identified it as that and failed to mention that.

Yes, the (3) batteries I hooked up were fully charged. School me; how is 35.3v only 30% of the pack on a 36v system?

This cart was working a few months ago before I got it so I can't imagine it's anything too terrible. I think the charger may be messed up now since he left it sitting on the cart in the rain, but I think the cart should be fairly simple. I just don't understand all of the operating system yet.

Raystar57

State of charge:

Attached Images

SOC-30%.jpg (65.5 KB, 0 views)

orangeman6

Well, I'm the wrong guy to school you, but if you look at the chart, you'll see the numbers. The chart is from johnnieb (complete propeller head, just read some of his posts). IIRC that chart is specific to Trojan batteries, but I don't think other brands are too different. Everyone here seems to use it. How is 35+ v only 30%? That answer is way beyond my pay grade. And, I'm not sure on, specifically, how low of a voltage the cart will respond to but I do know that is very low.

Below is the link to some diagnostics that may help you.




http://www.buggiesgonewild.com/elect...agnostics.html

Attached Images

IMG_0943.JPG (127.1 KB, 0 views)

kgsc

We need to know which controller you actually have because it has been changed out. A stock 05 would not have had an led light on the controller for series or PDS and from what you describe if it is a sepex cart and it was towed with the run/tow in run it could have fried the motor and controller. The controller obviously was but the motor may be shot too.

Txriverrat

Hopefully I can get some pics up tonight. I've been waiting for two days for my Photobucket to update and it's almost done.

Thanks for all of your input thus far!!

orangeman6

You can attach pictures right to your post. You may have to have a certain amount of posts to do it, but I don't think it's too many. Maybe 5???

Txriverrat

Thanks for the SOC chart. My decent math skills still don't let me understand how 35.3v is only 30% of a 36v pack, but I'll accept what it says. Hopefully tonight I'll have time to separate the pack into 3 and put some 12v chargers on them and see what happens.

Here are a couple of pics that I have with me. This is the old controller, but the one I replaced it with is the exact same part number.

Ok, so I can't get photos to load. The way I've always done it on forums doesn't work anymore since apparently Photobucket wants to charge for that now. I'll have to mess with that more later.

The controller is a Curtis 1243-4320 "SepEx traction controller"