1992 EZGO does not move

Jmiller48

I just purchased a1992 EZgo electric cart. Looks like previous owner tried new solenoid but it does not run. Solenoid clicks when key is turned on but that's it. Not really sure what to check first, he claims it needs controller but I'm not convinced yet. Any advise would be appreciated greatly.

BGW

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Sir Nuke

some of our REAL experts dealing with the electrical side will come to the rescue.......but for now........CONGRATS on the ride, and Welcome to our happy little corner of the net, and to BGW. There is a BIG fridge on the back porch with anything you can think of in it...help yourself...of course only take what you can LEGALLY have. Make yourself at home on one of the big fluffy couches, kick your shoes off, put your feet up on one of the tables, yes we are allowed to do that, mom's, wives', husbands, girlfriends and boyfriends here don't care....and take it easy.



oh...btw....every once in a while a food fight breaks out...so you may not want to wear nice clothes here.

Welcome!!

JohnnieB

Welcome to BGW!

The solenoid should not click until the pedal is pushed, so there may be some wiring issues or the pedal switch is bad or maladjusted. However, the solenoid does click, so the reason it doesn't run is in the high current circuit.

Connect your DVM between the B- and M- terminals on the controller.
When the solenoid clicks, you should read full battery pack voltage until your push the pedal.
(As you push the pedal, the voltage will decrease towards zero, but it's not running or sparking or smoking, so that probably isn't happening. )

If you don't get the voltage, there is an open somewhere in the cables and/or components highlighted on the attached schematic.

Attached Images

Pot Box cart with high current circuit traced.JPG (124.9 KB, 0 views)

Jmiller48

Thanks JohnnieB, I have swapped a few wires into the positions that they appear to need to be. Now I have battery voltage at the charge plug of 35.6v. I adjusted the pedal switch and the solenoid now clicks when pedal is pressed and forward reverse switch appear to be working as I get beeping when switched to reverse. I checked voltage between M- and B- as suggested. I do have 35.6v when solenoid clicks but it does not drop as pedal is pressed.

JohnnieB

Sounds like you got the control wiring sorted out, but the battery pack is extremely low. A fully charged 36V battery pack should read 38.2V, see attached chart.

Okay, you've got pack voltage between M- and B- when pedal is pushed just far enough for solenoid to click, but doesn't decrease when pedal is pushed to floor. That means either the throttle input to the controller is bar or the controller is bad.

To check the throttle input, unplug the small black and white wires from controller and measure between them with an Ohmmeter.
You should get around zero Ohms with the pedal up and about 5,000 Ohms with pedal down.
If you don't, the throttle is bad.
If you do, the controller is bad.

Attached Images

JohnnieB's SoC Chart.JPG (66.2 KB, 0 views)

Jmiller48

It looks like I have 1.5 ohms with pedal up and 6078 when fully depressed. Not sure if these are close enough to spec to be ok.

JohnnieB

That is in the ballpark, so it should run if the controller was doing its job.

If you are planning on doing anything except using the cart to haul two golfers and their clubs over groomed cart trails, you need something more robust than a stock controller and this would be a good time to upgrade.

Here is a pretty good overview on upgrading carts: http://www.cartsunlimited.net/Custom_Options.html

First step is figuring out what you want to do with the cart and then go from there.

Jmiller48

Thanks for all the help. Just some advise on controller packages from the link you posted. What version would I need for my cart keeping in mind the addition of a rear seat and slightly bigger tires?

scottyb

I like to have a little more information but generally speaking. Bigger tires increase the final gear ratio on average 30%. That decreases torque about the same amount. The rear seats weigh about 100-150 pounds. Add 2 more passengers to that and you have added load and decreased power (torque).

Jmiller48

Now I really need help. I replaced everything in this cart doing a rebuild. I have new controller, motor, cables and solenoid. I had a click from solenoid before I took it apart now I do not. I must mention when I put it back together I think I had the orange and black wires on the solenoid switched, thus causing some smoke from the pot box. I assume that this is now bad. Is there anything that I may be missing? With everything new I would assume it should work. I am beyond frustrated. Any help would be spectacular. I do have a new pot box ordered but now I'm afraid to try it when it does come for fear of ruining it.