New batteries - spark - now no go

sleepyluke

I know there are a couple of threads with different issues, but this one is via telephone. Paw in law installed new batteries in grandma in laws cart last night. When he put the negative wire on, it sparked, he pulled it off and reset it, no spark second time. It will not run, no reverse buzzer, nothing as he says. He did not know whether or not it clicked when pushing the gas pedal, that is the first thing to check tonight when he gets home.

He owns a series cart, and talking to him this morning, it sounds like Grandmother's cart is PDS, it does have run/tow switch which he thinks probably did all of this with it in the run position, not knowing he should have swapped it. I have not seen this cart in a while, has not run in over a year that I know of.

I will be there this weekend to see what I can do to help, but he is trying to use it this weekend for a wedding, so one less thing to fool with Friday night would be great if I can talk him through a few things to check.

I am going to send him the diagrams from the site for the wiring just to be sure that he did not cross something.

I know there are some dummies that work on these things at courses all day long and they don't fry the controllers every time they work on them, but without seeing it, is there a spade fuse in the controller itself, if so, what should I tell him to replace it with? Same, larger?

My first suggestion was to turn the tow swithc, let it sit for a few minutes and switch it back to see if it would reset without doing a whole lot to it.

Thanks for putting up with a repeat question via phone!

BGW

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subby44

Is he sure he has the pos and neg hooked up correctly? Maybe he does not have all connections tight enough... have him tug and pull on EVERY cable. I doubt he fried the controller. However, there is always the chance of it..

scottyb

It is VERY important to turn the run / tow (R/T) switch to Tow prior to doing any electrical work on these carts. That is why it is there and previously it used to be call a run / maintenance switch. He could have fried the control. There are no fuses OEM but, I have seen many people do the reed switch bypass and use a 60 amp charger fuse at the positive connection, In the case of a short the micro switch in the peddle box is usually the burned out link.... somebody needs to get a voltmeter out and see why the solenoid is not clicking... meantime ask him to charge the new batteries so the pack is ready to go when you get there. Bring this chart.

Attached Images

Ezgo PDS solenoid activation diagram.jpg (142.4 KB, 0 views)

JohnnieB

With a Run/Tow switch, it is either a DCS or PDS.
Need to know which it is to troubleshoot.
Pre-2000 is a DCS
Post-2000 is a PDS.
In either case, both the solenoid and beeper are controlled by the controller and if neither works, there is a possibility the controller got zapped.

Some sparking occurs when the final battery connection is made since the filter capacitors in the controller discharge when the battery pack is disconnected.
The size of the spark depends on how long the battery pack was disconnected.

Have him check the battery orientation. It is easy to get one or two reversed.
Hers is a drawing showing proper orientation, note the rear row is the opposite of the front row.

Attached Images

Battery Wiring - TXT and Medalist.JPG (75.9 KB, 0 views)

sleepyluke

it is supposed to be a PDS, with the f/r on the dash, but he thinks it is a 96. I will get him to read me the serial number tonight to track down exactly what it is.

Pedal box is a good thought and I will have voltmeter this weekend, and I think he has one, so I may be able to talk him through a few things tonight.

I have sent him the pics form here as well as the diagnostics post from ScottyB.

I have an all new respect for you guys that help us dummies by phone and email. He can fix anythign but sometimes gets a little short fused and makes it worse, so I hope he has not gotten there yet and I can talk him through it.

subby44

maybe i am related to him ( short fuse ) I am the same way... i am learning to calm down in my older age... best of luck to ya!!

scottyb

A pre 2000 with a run/ tow switch is a DCS cart.

chasenfish16

Johhnie B Can I ask why you connect the Main positive wire first before the rest of the wires? Just curious, about to put new batteries in my cart tommorow.

JohnnieB

What I posted is a cut&paste from a service manual.
Exactly why EZGO recommends connecting the cables in that specific order, I don't know.

I can't think of a technical reason for connecting the cables in that particular order, but it is emphasized in the manual, so there may be a reason for it that I'm not aware of.

sleepyluke

Cart is officially a 2000 PDS. There is apparently something on the body in marker that starts with 96, so he thought that was 96 which did not make sense. I ran the serial number and got the real scoop. He did not get a chance to work on it last night but going to try today.