EZGo Shuttle Ain't Goin'

wakeworld

My 1997 48-volt EZGo Shuttle 6 was working fine. Then while I was driving something happened. It stopped going and I ended up with just a little bit of movement at the rear wheels when I pressed the pedal. It wouldn't move, but you could see that it was trying. Once I got it up on jack stands, the wheels will move very slowly in forward and reverse. So I got out my trusty EZGo manual and voltmeter and got to work.

Batteries are strong and charged (reference voltage 51.4). Solenoid and ITS test ok. When I get to the controller test everything seems fine until I get to where I put the positive lead on terminal #3 (white wire) and press the accelerator. It's supposed to slowly get up to 2-5 volts below reference voltage. However, the voltage reading goes from 0 to about 11 volts and stops there.

According to the manual, this indicates a bad controller, so I sent it in to be rebuilt. When I got it back, I had the same problem. I assumed they did not fix the controller, but before sending it back I swapped out my controller with one from another cart that I know is working and I ended up with the exact same problem.

This is where I'm stuck. I know at least one of these controllers is good, but the test says they are both bad and my cart is not working. Any ideas?

BGW

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radioman

I would have tried the one repaired that didn't work in the donor cart before sending it back. But you have furnished enough info someone here can help you.

JohnnieB

What is the manual# on the manual you are using?

With the pedal pushed just far enough for solenoid to click, the White wire (Terminal-3) should read 1.6V
With pedal pushed to floor, it should read 2.5V.

With the pedal pushed just far enough for solenoid to click, the Black wire (Terminal-2) should read more than 10V, but less than 11V.

With the pedal pushed far enough for solenoid to click, the Red wire (Terminal-1) should read full battery pack voltage.

When solenoid is de-energized, the Red wire may read a few volts less than full battery pack voltage if there is a pre-charge resistor installed across the solenoid's large terminals, otherwise it will read Zero.

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If the solenoid is clicking when Pedal is pushed, the problem is most likely in the High Current circuit.

Connect the Negative test lead to the controller's B- terminal and the Positive test lead to the controller's M- terminal.

Disregard any voltage reading prior to solenoid clicking.
Press pedal until solenoid clicks. You should read Full Battery Pack voltage.
If not, the is an open or bad connection in the High Current circuit. F/R contacts or a corroded cable connection are at the top of the likely suspect list.

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Also, you said that it seems like the cart tries to move.
Have you check for stripped splines in one of the rear hubs?

wakeworld

I'm not sure. It's the "Electronic Speed Control" section out of a manual that I printed out a while back, so it doesn't have the cover information.

It passes all these tests.

The solenoid does click. I've tried two solenoids and I get the same result.

It reads 49 volts vs. battery pack voltage of 51. What is the "high current circuit?" Which cables should I look at for corrosion?

I did check and this doesn't appear to be the issue. The motor never spins up to any significant speed.

wakeworld

Oops, I forgot to say thanks for your help!!

yurtle

What's the file name of the manual? I'm assuming it's a .pdf.

yurtle

If you only have a hard copy, there are several manuals in the Stickies.

JohnnieB

1. Here is a PDF version.
2.
3.
4. That is a bit low. You have a high resistance connection someplace. The high current circuit is everything highlighted on attached schematic, plus the seven cables connecting the eight batteries in series.
5.

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The voltage (49V) you got between B- and M- ought to be high enough to check if the controller is doing its thing.
Press the pedal to floor (With rear wheels off ground).
Voltage should decrease to near zero.
If not, you also have a controller or a throttle issue in addition the excessive resistance in the high current circuit.

Attached Images

Shuttle 48V series schematic-1- High current traced.JPG (99.2 KB, 0 views)

Attached Files

cargo shuttle, shuttle,electric,6,28318G01R.pdf (16.13 MB, 0 views)

wakeworld

I can't find the file from which I originally printed it. I'm not sure where I got this document. I may have come with the cart.

wakeworld

Voltage decreases to around 36 volts when I push the accelerator all the way down.