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Old 09-20-2014, 10:38 AM   #1
bokeasmowl
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Default odd problem with our ezgo

We have been having a problem with our ezgo. First off, it's a series cart, Alltrax 4855, DnD speed/torque motor, White Rodgers solenoid...not sure of the model but it's a 48v version with square top and round body, it also has a resistor on it.

Problem we're having is that sometimes it does nothing. Sometimes it runs great and sometimes it'll run great and then leave us stranded from home.

At times when we are about to ride it won't move. Solenoid clicks but nothing. The control will flash it's correct sequence and then burn a continuous green. The other day the wife were riding for about a hour, came to stop at an intersection and when we went to continue...nothing. Just the click of the solenoid. As you can imagine, this is very annoying.

I'll have to pick up a dvm as I don't own one, or really know how to work one. I'm electrically challenged. Any suggestions as to the problem or cure is much appreciated. Thanks.
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Old 09-20-2014, 12:13 PM   #2
JohnnieB
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Default Re: odd problem with our ezgo

Sounds like a F/R switch issues. (The high current contacts overheating)
A 500A controller feeding a motor that can draw a lot of amps can take out a stock F/R whether or not you are running tall tires.

You'll have to do some troubleshooting to be sure, but if it is, replace it with the Heavy-Duty F/R from Carts Unlimited, (It is the heaviest heavy-duty F/R switch available): http://www.cartsunlimited.net/F_R_Switch_Upgrades.php

Or install the reversing contactor set up he sells: http://www.cartsunlimited.net/Reversing_Contactors.html
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Old 09-20-2014, 03:18 PM   #3
bokeasmowl
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Default Re: odd problem with our ezgo

My f/r is a heavy duty club car unit. My buddy installed it years ago, actually it's in its second cart now.
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Old 09-20-2014, 03:37 PM   #4
JohnnieB
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Default Re: odd problem with our ezgo

Still sounds like a F/R high current contacts issue.

But could be an ITS issue.

When you get a DVM, take it with you and when the cart misbehaves, connect the test leads to controller's B- and M- terminals.

Push the pedal just far enough for the solenoid to click.
You should read full battery pack voltage. (Check pack voltage first)

IF you don't get it, check the voltages on the high current cables on the F/R switch. There should be full pack voltage on all four of them.

IF you do get it, push pedal slowly to floor and the voltage ought to decrease to zero.

If not, connect the DVM leads between pins 2 & 3 on top of controller (Black and White wires).

When solenoid first clicks, you should read 10V
When pedal is on floor, it should be 6V.
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Old 09-20-2014, 06:08 PM   #5
bokeasmowl
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Default Re: odd problem with our ezgo

I got to looking more closely at my f/r switch today. The buss bar is worn a bit, go figure after 8 yrs of service. But I disconnected the blade connectors to the micro switch and wiped them off with my fingers and it moved. Mind you, the cart moved under its own power earlier when I moved it out the driveway without doing anything. We ran to Wal-Mart for a few things and when we got back thought we would go for a ride but it did nothing again. That's when I wiped off the contacts on the micro switch. I don't know...I need to get a dvm, but in the meantime we are gonna go ride the hood. Wish me luck.
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Old 09-20-2014, 06:48 PM   #6
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Default Re: odd problem with our ezgo

Well, it did it again. Ride around for 30 minutes or so and on the way back home it cut off about 3 miles from the house. I began to push it and benefited from a slight downhill where I could ride instead of push. When my wife caught up to me I tried the cart and it took off. We managed to be able to ride it the rest of the way home. Thus is sooo annoying.
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Old 10-09-2014, 08:47 AM   #7
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Default Re: odd problem with our ezgo

Took the cart last week to a local ezgo dealer. Service tech called my yesterday and said the ITS was cracked. He replaced it but it still does the same thing. And at the $168 price of the ITS, I told him to take it out. I see them on eBay for $45 all the time. Then he tells me my controller is bad. Wanted to know if I want him to order one to the tune of $700. Hell no I don't. Errrr.... I need to get a dvm and force myself to learn how to trouble shoot this thing.
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Old 10-09-2014, 09:28 AM   #8
Bmatlock00
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Default Re: odd problem with our ezgo

i had the same problem on my EZGO about a year ago and it turned out to be the solenoid, even though it was still clicking. It would run fine for a while then quit. I took a dvm and short battery cable and rode around until it quit, I checked the voltage across solenoid and it was not closing, so I jumped it with the battery cable to get me home. Changed out the solenoid and it has ran fine since. It does not seem to be a very common on here, but solenoid can be bad even though it is clicking.
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Old 10-09-2014, 10:55 AM   #9
scottyb
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Default Re: odd problem with our ezgo

Quote:
Originally Posted by Bmatlock00 View Post
i had the same problem on my EZGO about a year ago and it turned out to be the solenoid, even though it was still clicking. It would run fine for a while then quit. I took a dvm and short battery cable and rode around until it quit, I checked the voltage across solenoid and it was not closing, so I jumped it with the battery cable to get me home. Changed out the solenoid and it has ran fine since. It does not seem to be a very common on here, but solenoid can be bad even though it is clicking.
It's rare but, it does happen. The intermittent problems like this on can only be diagnosed when it's not working. It's not fun but you gotta be prepared to stop and T-shoot wherever whenever. Carry a DVM, a small tool kit and the jumper cable mentioned.
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Old 10-09-2014, 11:15 AM   #10
mgray70
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Default

You can get a nice 400 amp Alltrax axe or SPM got under $500 if you have to have a controller.
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