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Old 04-06-2019, 03:00 PM   #1
PingEye3
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Default 2003 EZGO Freedom Series w 1205 Controller

Stumped on this old cart. This cart has, I think, a 1205 controller w/4 blade control terminals and lever & linkage controlled FNR switch. I replaced this swith about a year ago for this member at the club. Last Sunday, it got to the point where he could not get it to run in reverse. He would move the lever a little and then get it to move ocasionally. Today, I did some troubleshooting on it. Reverse buzzer works when placed in reverse. Orange wire to controller pin 4 was @ 38.6V (PV) when placed in reverse, solenoid will activate with foot switch. Cart runs fine in forward, but will no onger run in reverse. There is nothing burned or corroded on this switch as it still looks like new.

So, if I have power on pin 4 of controller with orange wire when in reverse, it should run in reverse. It it possible for 'part' of the controller to go bad, meaning reverse.

I used the attached diagram for the cart. The only thing different from his cart and this drawing is that he has the reed switch in the charger receptacle feeding to the MS2 - MS4 common point.

Sound like something easy for JohnnieB or cgtech
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File Type: jpg EZGO 4 blade Curtis 1205 wiring.jpg (61.7 KB, 0 views)
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Old 04-06-2019, 05:12 PM   #2
JohnnieB
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Default Re: 2003 EZGO Freedom Series w 1205 Controller

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Originally Posted by PingEye3 View Post
Stumped on this old cart. This cart has, I think, a 1205 controller w/4 blade control terminals and lever & linkage controlled FNR switch. I replaced this swith about a year ago for this member at the club. Last Sunday, it got to the point where he could not get it to run in reverse. He would move the lever a little and then get it to move ocasionally. Today, I did some troubleshooting on it. Reverse buzzer works when placed in reverse. Orange wire to controller pin 4 was @ 38.6V (PV) when placed in reverse, solenoid will activate with foot switch. Cart runs fine in forward, but will no onger run in reverse. There is nothing burned or corroded on this switch as it still looks like new.

So, if I have power on pin 4 of controller with orange wire when in reverse, it should run in reverse. It it possible for 'part' of the controller to go bad, meaning reverse.

I used the attached diagram for the cart. The only thing different from his cart and this drawing is that he has the reed switch in the charger receptacle feeding to the MS2 - MS4 common point.

Sound like something easy for JohnnieB or cgtech
The controller in a series cart doesn't know the difference between forward and reverse. Direction switching is external to controller.

The Orange wire is 1/2 speed and it typically used whne direction selector is in reverse, but can be used at any time by putting pack voltage on it.

Connect your DVM between the B- and M- terminals. Push pedal just far enough to make solenoid click, or jumper B+ to small terminal; with red wires on it to keep solenoid closed without pushing pedal

You will get full battery pack voltage between B- and M- when solenoid contacts close, if you don't there is an open in the high current circuit. F/R contacts are most likely suspect since cart runs in forward. The only difference between F and R is which contacts are making in the F/R switch.

With reverse selected and solenoid contacts are closed, check the voltage on the four studs on the F/R. They should all have pack voltage. The open will be between where the voltage is and isn't.
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Old 04-06-2019, 05:14 PM   #3
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Default Re: 2003 EZGO Freedom Series w 1205 Controller

Also, put cart on jack stands so it doesn't take off unexpectedly and run over something or someone.
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Old 04-06-2019, 05:26 PM   #4
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Default Re: 2003 EZGO Freedom Series w 1205 Controller

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Also, put cart on jack stands so it doesn't take off unexpectedly and run over something or someone.
Thank you JB, I knew you would have some help here. May get to the cart tomorrow, but will check all asap.
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Old 04-06-2019, 10:48 PM   #5
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Default Re: 2003 EZGO Freedom Series w 1205 Controller

JohnnieB -
I thought about the power cables at the FNR switch and though I did not check electrically as you suggested above, the switch is about a year old (I replaced it) and still looked like brand new and in very good contact, in Fwd or Rev

I remembered one thing that may be an issue, which I ignored because I was focused on 'why' no reverse. When I drove the cart in forward, there was a sudden launching of the cart, with what I now remember would be too much pedal movement before the cart moves. Like no cart movement before 1/2 throttle and then a sudden take off.

My brainstorm . Could the ITS throttle be defective or grossly out of adjustment? If so, with the 1/2 speed orange wire connected to Pin 4, would a throttle issue like that prevent the cart from running in reverse or intermittenly as it has been doing?
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Old 04-07-2019, 08:16 AM   #6
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Default Re: 2003 EZGO Freedom Series w 1205 Controller

Ping....seeing as how its been a good while since you put that F&R in, its possible the tension on the contacts has loosened, there is a single nut on the center shaft, tighten it up a bit and see if you now have reverse.
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Old 04-07-2019, 12:38 PM   #7
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Default Re: 2003 EZGO Freedom Series w 1205 Controller

The FNR switch is not going fully to reverse. All four connection studs are in use in forward AND reverse, so if they were failing, you'd have a problem in forward. The FNR is mounted to a bracket that has slots on the mounting bolts that attaches to the frame. Move the FNR to EXACTLY halfway between forward and reverse - Neutral - then loosen the bolts and move the bracket from side to side until the FNR handle is in Neutral.

If that doesn't work, tear the FNR apart, inspect, clean, and tighten the middle nut until he can't easily move the lever, then back off just a tad. With dielectric grease, I keep mine tight.
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Old 04-07-2019, 12:58 PM   #8
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Default Re: 2003 EZGO Freedom Series w 1205 Controller

The beauty of measuring the voltage between B- and M- when the pedal is pushed just far enough to make solenoid contacts close, is that it places a single open (the turned off MOSFETs) in a series circuit, so if you don't get the full battery pack voltage across the known open, there is at least one other (undesired) open in the circuit, or excessively high resistance.

It is the best first step test I know of if the solenoid clicks when the pedal is pushed.

--------------
You might have something there about a throttle issue. If it is an ITS type throttle measure the throttle voltage at the controller. The throttle voltage specs are unique to the make/model of the controller, so you'll have to look it up. It probable won't be the same as for a standard series controller (Curtis 1206).

Try disconnecting the orange wire. Then R ought to act the same as F.
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Old 04-07-2019, 02:04 PM   #9
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Default Re: 2003 EZGO Freedom Series w 1205 Controller

Quote:
Originally Posted by JohnnieB View Post
The beauty of measuring the voltage between B- and M- when the pedal is pushed just far enough to make solenoid contacts close, is that it places a single open (the turned off MOSFETs) in a series circuit, so if you don't get the full battery pack voltage across the known open, there is at least one other (undesired) open in the circuit, or excessively high resistance.

It is the best first step test I know of if the solenoid clicks when the pedal is pushed.

--------------
You might have something there about a throttle issue. If it is an ITS type throttle measure the throttle voltage at the controller. The throttle voltage specs are unique to the make/model of the controller, so you'll have to look it up. It probable won't be the same as for a standard series controller (Curtis 1206).

Try disconnecting the orange wire. Then R ought to act the same as F.
Doh! Too obvious, and easy.
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Old 04-07-2019, 07:51 PM   #10
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Default Re: 2003 EZGO Freedom Series w 1205 Controller

Too obvious or not, removing the orange wire and cart runs fwd and reverse just fine but with a jumpy throttle. I had the owner pull the orange wire and test it when he got back in town this afternoon.

Can't believe it is turning out to be that simple. I will check the FNR switch thoroughly as suggested, when I go back to check out the throttle. I will update with what I find out
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