Ezgo shuttle wiring issues

Jimmyboi082

I just purchase a 2008 ezgo Trexton shuttle. The guy I got it from said all it needed was a solenoid and batteries. I got batteries 48.7v showing. Installed the solenoid and it doesn't go. It has a Curtis model 1264-5407 controller. Shouldn't the controller flash a code telling me something is wrong. It has no flashes. Also the charge port wires( black,white) don't run to the batteries it's connected to the controller is that normal? I'm thinking something is not wired correctly what is the wiring diagram for it.

BGW

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JohnnieB

New batteries ought to be charged prior to first use and after every use thereafter. At 48.7V, your batteries are only about 55% charged and they should never be discharged below 50%.

The black wie from the charging port connects to the B- terminal on the controller and the white wire connects to the battery side large terminal on the solenoid, however they could be connected to the main B+ and B- terminals on the battery pack if so desired. Some shuttles have a removable battery pack so the charging cables were not connected to the battery pack on the carts without the removable pack also.

Here is a schematic for a 48V sepex drive shuttle with a 1264 controller, a list of the error codes and a State of Charge chart.

Attached Images

	PDS-II Shuttle.JPG (94.6 KB, 0 views)
	Shuttle Svc Man Page G-25.jpg (254.0 KB, 0 views)
	Shuttle Svc Man Page G-26.jpg (181.6 KB, 0 views)
	SoC vs Voltage - Trojan Battery.JPG (56.9 KB, 0 views)

Jimmyboi082

So hooked it up the way it shows. Will it still move with 55% voltage? The controller flashed a code 3-1. Is that a false code because the voltage is low or is it going to be a controller problem?

JohnnieB

It ought to move with 55% SoC, but I'm not sure if it would make the controller issue false error codes.

Charge the batteries and try it.

Jimmyboi082

I charged the batteries to 50v and controller still shows 3-1 code to replace controller. Are controllers rebuildable?

JohnnieB

Even if you found a place that could repair it, you'd still have a 20 year old controller based on even older technology.

Replace it with an Alltrax XCT4800-1264/1268 (or larger) controller.

Jimmyboi082

Before ordering a new controller is there a test I can do to confirm that the controller is the problem? Is there a way to test the motor to see if it works? I don't even know if it works and I don't want to replace the controller and find out it doesn't even work.

JohnnieB

Attached is a way to check a sepex motor.

The following condition must be true to get the solenoid to click when pedal is pushed.
1. Run/Tow in Run
2. Direction selected on F/R
3. Keyswitch on
4. Pedal pushed

Find the pins on J1 that are fed by the above switches and verify that there is 48V on those pins when the switches are set for the cart to be driven.

Attached Images

Motor Test - Sepex.jpg (91.7 KB, 0 views)

Jimmyboi082

I was checking the ITS. Used my ohm meter and showed 3.76 m ohms all the time even fully depressed is that normal or should it increase and decrease as I push and release the pedal.

JohnnieB

The input to the ITS sensor is a bridge rectifier, so with an Ohmmeter it will measure about the same with either polarity and with the pedal up or down. (schematic attached)

Measure the voltage between the white wire and B- at the battery pack. When the pedal is pushed just far enough to make the solenoid click, the voltage should be 1.0V +/- 0.3V and them with pedal on floor, it should be 2.7V +/- 0.5V. (Mote to future readers of this spec. the voltage is determined by the controller, in this case a Curtis 1264)

Attached Images

ITS sensor - Schematic.JPG (88.3 KB, 0 views)