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Electric EZGO Electric EZ GO Marathon, Medalist, TXT and RXV.



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Old 01-22-2012, 11:14 AM   #1
ruhrow
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Default Replaced batteries, now cart is dead.

My cart is a TXTPDS with date code of K1701.

I purchased a used cart that I assumed needed new batteries. The cart ran ok. But, the cart died after 9 holes of golf.

I inspected the batteries and some looked swollen. I took them to NAPA and they found one battery was bad. I went ahead and purchased 6 of the NAPA brand batteries that crossed referenced to the old Trojan t-105's.

After installing the new batteries and cleaning/painting the battery trays, I thought I would be good to go.

After I was done with the battyer swap, the cart seems dead. I turn on the key and put it in reverse and nothing. No clicks, no reverse sounder, nothing. I put the carger on it and saw about 4 quick red flashes on the LED then the "normal" green blinking. I see that all the battery cells are bubbling during the charge. I see 38 v at the charging socket . I was careful to document, draw, and photograph the wiring before I started the battery swap.

I'm pretty sure I had the switch in TOW mode before beginning the battery swap.

Any help you can provide would be greatly appreciated.
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Old 01-22-2012, 01:56 PM   #2
JohnnieB
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Default Re: Replaced batteries, now cart is dead.

Be sure to give the new batteries a full charge before first use and they have to be broken in properly to get maximum storage capacity.
http://www.cartsunlimited.net/Batter...n_Methods.html
While on website, read everything with "Battery" in title.

Be sure batteries are wired same as shown in attachment-1
Check for Battery pack voltage (38.2V full charge) on small white wire coming out of charger receptacle. If not there, attach BL+ to Red wire it plugs into.
(BL+ is Positive terminal of Right Front battery)
There is a Reed Switch (safety interlock) in the charger receptacle that shuts down cart when charger is plugged in.

Hopefully charger plugged wasn't attached to cart when you tried it.
Attached Images
File Type: jpg Battery Wiring - TXT and Medalist -No Text.JPG (30.9 KB, 8 views)
File Type: jpg Charger receptacle with top off.jpg (71.7 KB, 11 views)
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Old 01-23-2012, 12:40 PM   #3
ruhrow
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Default Re: Replaced batteries, now cart is dead.

Thanks for your response.

With the charger disconnected, the key ON, switch set to FWD, and run/tow set to run:
Voltage at outside lugs of the charging socket shows 38v

The thin red wire coming out of the back side of the charging socket has an inline disconnect. I disconnected it and saw 38v on the wire coming from the back of the charghing socket.
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Old 01-23-2012, 02:14 PM   #4
simple man
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Default Re: Replaced batteries, now cart is dead.

Double check that you didn't leave any smaller wires disconnected, that are taps on the batteries. It is so easy to do! I'm glad you took a photo. That makes things a lot easier to reconnect. Check your small plug on the controller, it may have been bumped loose. Also check any plugs that could have been knocked loose in the process. I'm sure it's a simple connection problem!
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Old 01-23-2012, 03:10 PM   #5
ruhrow
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Default Re: Replaced batteries, now cart is dead.

There were only two wires other than the main power cables. One is white with the fuse link that is connected to the positive side of the battery array and the black wire that is on the negative side. Both wires are intact and in their original positions.

Is there an easy to bypass the on/off key switch or the fwd/rev switch?

Thanks for your advice.
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Old 01-23-2012, 04:40 PM   #6
scottyb
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Default Re: Replaced batteries, now cart is dead.

First check for power (+) at the small red wire at the rear of the charge receptacle as shown in the post #2. If no power present run the wire to the battery pack + and see if the cart runs.
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Old 01-24-2012, 06:56 AM   #7
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Default Re: Replaced batteries, now cart is dead.

Quote:
Originally Posted by ruhrow View Post
..............Is there an easy to bypass the on/off key switch or the fwd/rev switch?.............
I believe it is safer to troubleshoot with Voltmeters and/or Ohmmeters than using jumper wires.

If you haven't already, go to the STICKY:s at the top of the Electric EZGO forum and download the Owner, the Service and the Parts manuals for you cart.
They are the 3 ".pdf" files here:http://www.buggiesgonewild.com/elect...g-manuals.html

Attached is the schematic for a PDS cart.
As you see the solenoid is activated by the controller and for that to happen 5 switches must all be closed.
1. Reed Switch. B+ to J1-P4.
2. Key Switch. Shorts J1-P8 to J1-P9
3. F/R Switch. Shorts J1-P1 to either J1-P2 (R) or J1-P3 (F)
4. Run/Tow Switch. Shorts J3-P1 to J3-P2 and J3-P3 to J3-P4
5. Pedal Switch. Shorts J4-P1 to J4-P2

You say you've got B+ on small wire coming out of charger receptacle, so it should be present at J1-P4 there unless Red wire is broken or disconnected, but I would check for its presence with a voltmeter just to be sure.

I would also Check for B+ on J1-P5. That comes from the battery side main terminal of the solenoid.

Switches #2 through #5 above can all be checked with an Ohmmeter by unplugging the plugs at the controller and measuring across the specified pins while toggling the respective switches.

Be sure to put Run/Tow switch in Tow before unplugging any plugs.

Let us know what you find.
Attached Images
File Type: jpg Wiring Diagram - PDS.JPG (64.6 KB, 6 views)
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Old 01-24-2012, 11:58 AM   #8
ruhrow
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Default Re: Replaced batteries, now cart is dead.

I checked all 5 switches at J1 and they all checked out ok.

I checked for voltage at J1-P5 and found zero voltage!

What do you recommend?

Thanks again for your patience with this golf cart rookie.
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Old 01-24-2012, 12:36 PM   #9
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Default Re: Replaced batteries, now cart is dead.

Quote:
Originally Posted by ruhrow View Post
1. I checked all 5 switches at J1 and they all checked out ok.

2. I checked for voltage at J1-P5 and found zero voltage!
1. The switches connect to controller via J1, J3 and J4, but if they all checked good, great.

2. J1-P5 gets B+ from Battery side main terminal on the solenoid. The small red wire coming off that terminal also feeds B+ to the the Reverse Beeper, so there is a connection of some kind in the wire loom.

I'm not sure where the connection is exactly, but just start at the red wire on the battery side main terminal on the solenoid and trace it to the connector going to the Reverse beeper in the dash. (Should be a 2 pin connector with a Red and a Grn/Blk going towards front of cart.) From there it should go back into the loom and end up at J1-P5.
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Old 01-24-2012, 12:40 PM   #10
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Default Re: Replaced batteries, now cart is dead.

There is a sonic weld in the loom just where it exits the battery bay
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