97 EZGO 36V DCS Runs for a few seconds, Stops

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I have a 1997 EZGO Medalist 36 Volt DCS Golf Cart. It's all stock.

History:
It's new to me... It came with no batteries so I put new batteries in it and hooked everything up. Full Disclosure; The Batteries are unused Deka GC10 from 2015. They were old stock and never installed. They have a three year warranty so are still under warranty and I was told they are good. The water level looks good on all of them, so I charged them up. Meter shows about 6.2 Volts on each battery.

The Problem:
It will run for a few seconds, then stop. If I switch it to Maintenance mode and wait about 10 seconds, then switch it back to run, it will go for another few seconds then stop. I can repeat this over and over.

When it stops I do NOT have battery Voltage at B+. When I switch to Maintenance mode I can watch the voltage at B+ climb from like 0V - up to 35V. Then when I switch to Run I get about 37.2v. This entire time, the voltage across the Batteries is always 37.2V.

I already replaced the Solenoid because it came with an extra one, and same results. WTF? Any help?

BGW

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JohnnieB

For starters, the battery pack needs to be fully charged. (An at-rest voltage of 37.2V is only 75% charged.)

Sounds like the solenoid contacts are not closing. Could be a bad solenoid, or a bad controller, or some bad switches, wires or connections

Verify you have battery pack voltage (38.2V when fully charged) on the solenoid's small stud with three wires on it when Run/Tow is in Tow, Direction selector is in F and keyswitch is ON.

If so, verify battery pack voltage on the soleniod's small stud with a single blue wire on it.

When the pedal is press, the voltage on the blue wire ought to drop to zero and the solenoid ought to click.

Attached Images

Wiring Diagram - DCS - No Reverse Diode -KSI Traced.JPG (94.7 KB, 0 views)

ZoomZoom

Okay my battery voltage when disconnected is 38.3v

I have two solenoids and I did test them both with a Multimeter. I connected the meter across the two large terminals in continuity mode, then applied battery voltage across the small terminals. They both opened and closed as they should and they make a pretty loud click.

I did not remember hearing that loud click when I pushed the gas pedal, so I think you're right so this time I watched the voltage on the Blue Wire going to the Solenoid and the voltage is only 27.3V. When I hit the go pedal It never drops to 0v/Ground so the Solenoid is not closing. Is it normal to see a 10V drop on the Blue Wire? I checked it at Pin 7 and at the Solenoid terminal and both read about 27-28 Volts so it's not a wiring issue.

I did not realize the motor would run without the Solenoid kicking in...

So why isn't the controller dropping the Blue Pin to ground? Outside influence, or bad controller?

I started down the Control Circuit troubleshooting path; step 2 says Walk-away Operative & Able to get into Reverse & Reverse Buzzer Operative.

My buzzer is not working, so does the Controller know the buzzer is not working?

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Walk-away does not seem to be working either. I'm starting to think I have a bad controller...

JohnnieB

Check the voltage on Pins 6, 9 & 10 on top of controller, all ought to be at full pack voltage when pedal is press (9&10 have voltage before pedal is pressed)

If you are missing any one of the three, or if it is much lower than pack voltage, the controller won't make the solenoid click.

If you have those three voltage and Pin-7 not dropping to about zero when pedal is pushed, the controller is bad.

The Curtis 1206SX controller used in DCS carts was a failed design, so don't replace it with another stock DCS controller. Install an Alltrax DCX or XCT controller and hold onto your hat. A DCS cart will do a bit over 20MPH on stock height tire and an Alltrax controller.

ZoomZoom

Yes, I went through all those voltage checks and they are good, but the solenoid never drops to ground on the blue wire... I think I'll send it in for repair because I don't want to drop $400 a DCX controller right now.

biphase

If you send it to me, I will fix it for free.

ZoomZoom

You've got a deal!

biphase

email: biphase2000@yahoo.com for shipping address

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I sent you an email.