Can anyone help me troubleshoot and find out why this is now working (electrically)??

Superman51

Hello everyone,
Background: 95 medalist series EZGO stock
I’m currently building my cart and have hit some major road blocks. I have another thread going but it was very broad and it was like trying to find a needle in a hay stack. Long story short, I upgraded my cables, F/R switch, solenoid, 48V, and motor and the cart wouldn’t run. After hours of trying to figure out why, I just started over from the beginning, where I knew it would. Starting from original, the cart will run with the 2 gauge cables on and at 36V (the pack runs like picture 1). I then tried to just go to the 48V system with all 2 gauge wires and the solenoid just clicks (running the cart like picture 2). I cannot figure out why my cart will not run on the 48V?????????? It should, right? This is the problem, I believe, that has screwed up my whole system! Here is a list of troubleshooting ideas that I have done already. I am literally out of ideas so any help will be greatly appreciated.

1. I tried using my old 6 gauge wires instead of the 2 gauge wires to add the 2 new batteries in
2. I tried different nuts
3. Checked, and checked, and checked, and rechecked the tightness
4. I ran the two new batteries in a different section of the 36V battery pack
5. Checked the voltage: Battery 1=6.5V/ Battery 2=6.5V/ together=13V /with the whole system=50.8V

Attached Images

	IMAG0059.jpg (48.3 KB, 8 views)
	IMAG0058.jpg (44.9 KB, 10 views)

BGW

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DOOmsman

When the solenoid clicks does it pass full voltage?

Superman51

Yes, there is 50V on the other side of the terminal when I press the throttle and it clicks

scottyb

Starting a new thread on an old problem is counter productive now when people read this they have none of the benefit of the things that were checked before. It is like having Alzheimer disease.

If the solenoid is clicking when you push the gas it sounds like the problem is in the main cable routes. Check your main cables against a diagram like this one. If your cart is cabled like this diagram and your solenoid clicks and your controller is wired per the manufactures diagram.... the cart will go

There really is no silver bullet ~ You will have to find where you made your wiring mistake or find what has failed by process of elimination and fix it.

Attached Images

AXE series Ezgo.jpg (114.7 KB, 28 views)

OU4LIFE

i'd rather have a magic bullet.

just sayin...

Good luck dude.

scottyb

It's Silver OU, like the Lone Ranger had. He went to OU, no?

Superman51

Scotty, I understand where you are coming from. But….. this has NOTHING to do with my old thread. I tried to tackle way to big of a job and there were just too many variables!

If you read my post, I started over from the beginning. It’s a 95 medalist (STOCK) with a 36V system. I then tried to just add 48V to my system. That is where my problem is. That has nothing to do with what I have done before so how is that counterproductive?

I listed everything I have done and now I’m just asking for any more trouble shooting ideas. I have my cart wired the way it was stock and it works fine. When I tried to add the extra 12V, I get the clicking noise.

scottyb

The battery pack configuration is correct that is not the problem, you have 50v. I think the problem is back on the other thread with all the work already done. That is why I said that .... I have posted another diagram for you to work with. I hope that helps.

madoc1

super, how about taking some acetone and wiping down all your wires and starting over again? pull up a chair , take the diagram, pull the tab on a brew and just study awhile while looking at the cart.

mauistardog

When you connected the wires to the motor did any of the studs spin ? Check your connections and studs on the motor.

just thinking out loud
aloha
joe