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Old 07-01-2011, 09:10 AM   #1
MACKM
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Default yet another issue

I am calling on the help of the pros yet again. I have a 1990 ez go electric cart. Around Memorial Day, I dealt with several problems leading me to replace batteries, a controller, pedal switch and connectors for the wiring.

New problem. About a week ago, I noticed that there was no low end torque. I mean the cart could not start out on it's own even on level ground. If I gave it a push, it would pick up speed and travel fine until I came to a hill where it would just stop. A full charge cycle did nothing to remedy the problem. I trickle charge the batteries two at a time and found that two of the batteries, (last two in the series) were not charging. Once I let those charge, the problem was gone. I figured it was the batteries and seeing they were only about a month old, I took them back and exchanged them for six brand new ones. I gave it a full charge over night. Pack is reading at about 41VDC. Still the same problem. I started to look into other causes and I found a suspect connection at the motor on the A2 terminal. I tried to remove it and wouldn't you know it, I snapped the post.

Where do I go from here? I can't prove that it was the connection that was slowing me down and now I have a motor with a broken post.

Help!

Thanks for reading.
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Old 07-01-2011, 10:08 AM   #2
MACKM
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Default Re: yet another issue

Well, I pulled the motor out and the post that had snapped basically crumbled in my hand. The insulation that keeps the post from the shell is toast. I have a call into my dealer for a price on a motor. My new question is, when I replaced the controller, they sold me a 400amp one which was an upgrade from the stock 275amp. Could this increase in amps cause the motor to fry? I am looking for a bargaining tool when negotiating a price on the motor.

Thanks again.
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Old 07-01-2011, 11:23 AM   #3
rabbitreborn
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Default Re: yet another issue

Yes, the increase in AMPs was probably the death knell for your motor.....

NO, don't call your dealer.... Call Plum Quick ...... Not only are they a sponsor here that helps keep these forums operating, but they are also fantastic guys to deal with and do QUALITY work at a reasonable price!
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Old 07-01-2011, 05:01 PM   #4
MACKM
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Default Re: yet another issue

Thanks for the reply. I have had a long day but here is where I am at. I caled this guy I know, he had an identical motor so I swung down there and bought it. 25$ was a steal. While I was there, I grabbed a new wiring kit. 4awg wires through out the whole cart now. New motor is in. (Easier than I thought it would be.) Turned it on, still slow moving cart. I am giving a charge now and I will report my findings. Can the new controller burn out just the low end power but still work fine on flat ground and high speed? If so, how can I test that without metering components at a whopping 15mph?

It's getting down right humurous now. This thing is killing me.

Thanks for reading.
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Old 07-01-2011, 09:02 PM   #5
MACKM
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Talking Re: yet another issue

After several adult drinks this holiday weekend, here is where I am at.

Even though my textron charger shut off meaning it has finished it's cycle, the cart still had no take off power. I broke out my trickle charger again. I am charging the batteries two at a time. The first two took about two hours and the same for the second two. It is now charging the third set. I believe that this proves my textron charger is not outputting properly. "outputting" is that even a real word? I metered my charger while it was charging the pack earlier and it was at 42vdc. Once I disconnected it, the pack voltage fell to 40.5vdc. So if after this third set finishes and if the takeoff power is back, it must be the charger right? Let me know if you agree or disagree.


Side note, I didn't just blow off the earlier reply when you said not to call my dealer. I have a relationship with them and they have been very helpful during my gold cart troubles. If I am ever afforded the time which would allow me to go through one of the sponsors here, I will.

Thanks again.
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Old 07-01-2011, 10:59 PM   #6
scottyb
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Default Re: yet another issue

This could all just be a battery problem. How old are the batteries? What is the total pack voltage when the charger is nearing the end of it's charge cycle? AND what is the pack voltage after sitting for 12 from the time the charger shuts off and again.... what is the pack voltage when you press the peddle and try to go? You will have to wire the meter to the pack for the last test = simple as duck tape.
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Old 07-02-2011, 12:23 AM   #7
MACKM
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Default Re: yet another issue

The batteries are brand new. They are not the holy trojans but they are new duracells. Pack voltage is 42.5vdc after a charge cycle. I will meter the volatge in the a.m. to see what they are after 12hrs. I will also do a ride along test of the pack voltage in the a.m. as well. I had a pretty nasty arc situation involving the solenoid about a month ago, just in case that could be related.

Thanks for the help...
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Old 07-02-2011, 07:53 AM   #8
shadowman
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Default Re: yet another issue

it could be the pot going.....they,ll do that.....check the micro switch on the F&R and make sure that arm on it isn,t starting to bend and roll over ..........i think its the left one but look at that before the pot....................................
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Old 07-02-2011, 08:59 AM   #9
MACKM
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Default Re: yet another issue

I do not have any micro switches on the F/R switch. I thought they only perform accesory options so I removed them.
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Old 07-02-2011, 09:21 AM   #10
scottyb
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Default Re: yet another issue

Quote:
Originally Posted by MACKM View Post
I do not have any micro switches on the F/R switch. I thought they only perform accesory options so I removed them.
Micro switches are safety devices. You do need one on the throttle to activate the solenoid & power up the controller, otherwise you have a key activated solenoid which will burn out in time. (If left on)
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