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



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Old 11-17-2014, 02:29 PM   #1
okie-dude
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Question 95 ez-go Medalist wont go

Hey everyone! I did some searching and couldnt find what i needed..

some background: I own a powersports/boat repair shop and work on yamaha gas carts from time to time and installed batteries in electric carts (also interstate dealer).

Anyways, had a customer talk me into working on his electric ez-go that wouldnt go, well im pretty savey at wiring boats/motorcycles but this electric cart is a bit different then i was expecting haha. Having a hard time finding a service manual or a trouble shooting guide.

The cart appears to be a 1995 medalist via the vin number, but it has a new looking 96+ txt plastic body on it in.

The cart died while bob (customer) was driving it down the road. He just bought the cart 2 months ago.

You can turn the key on, put it in forward or reverse, tow or run, depress the throttle pedal and nothing at all happens...

Batteries have 36.64 volts in them, they 6 month old interstate batteries.

From what i have seen, looks like there are some very knowledgeable people on here, any help will be very appreciated!
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Old 11-17-2014, 02:49 PM   #2
Olman
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Default Re: 95 ez-go Medalist wont go

Batteries are only at about 50% at 36.6 volts. Give it a good charge then see what happens.
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Old 11-17-2014, 04:00 PM   #3
sowilliams
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Default Re: 95 ez-go Medalist wont go

Service manual is in the Stickies
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Old 11-17-2014, 04:01 PM   #4
JohnnieB
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Default Re: 95 ez-go Medalist wont go

While you charge the batteries, let's see if we can identify what type drive system in in it, series or DCS.

Whatever it is, with the battery charger disconnected from cart, Run/Tow switch in Run (if it has one), keyswitch on and either F or R selects, the solenoid should click when the pedal is pushed. Does it?
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Old 11-17-2014, 04:51 PM   #5
okie-dude
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Default Re: 95 ez-go Medalist wont go

K, batteries are being charged

Thanks for the heads up on the sticky

Quote:
Originally Posted by JohnnieB View Post
While you charge the batteries, let's see if we can identify what type drive system in in it, series or DCS.

Whatever it is, with the battery charger disconnected from cart, Run/Tow switch in Run (if it has one), keyswitch on and either F or R selects, the solenoid should click when the pedal is pushed. Does it?
Sepex, DCS.

No, the solenoid does nothing.

Tested key switch, its good

The solenoid seems to work when i send 36v to it. It sends 36 volt from the battery post side to the controller/motor side. When then solenoid is de-energized "off" the voltage on the controller post side drops from 36v to 22 in about 3 seconds then stays at 22volts, is that normal? i drew a picture to better understand what i mean.(see attachment)
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Old 11-17-2014, 05:38 PM   #6
JohnnieB
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Default Re: 95 ez-go Medalist wont go

There isn't a service manual covering a 95 Medalist DCS in the stickies, however here is a link to where you can download it in a PDF format: http://www.ordertree.com/docs/1047/E...28124G01RS.pdf

Attached is a schematic with the solenoid activation circuit highlighted.

The voltage you are reading when the solenoid contacts are open, is low. It normally drops to about 3-5 volts below the pack voltage and stays there.

That is due to the fact there are a bunch of filter capacitors in the controller that are connected between the B+ and B- terminals and the resistor on the PCB connected between the solenoid's large terminals keeps them charged. The 3-5 volts is the voltage drop across the resistor due to the current flowing through it. You are seeing about a 12-14 volt drop, so something is amiss, but it is a secondary issue at this point.

First thing to do is get the solenoid to click when it is supposed to.

B+ gets to the solenoid's small with three wires on it via the reed switch, the Run/Tow switch, a switch on the F/R assembly and the keyswitch.

With those switches closed, you should measure FULL battery pack voltage on the small terminal with three wires. If you don't, trace back through the switches until you find it.

Check the voltage on the third (smaller) wire coming out of the charge receptacle. That comes from the reed switch and the reed switch is a common failure when the cart stops working suddenly.

If the reed switch is the problem, just land the wire on B+ someplace and bypass it. EZGO eventually stopped using reed switches because they stranded so many people out in the middle of nowhere.
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File Type: jpg Wiring Diagram - DCS- Primary KSI Traced.JPG (116.6 KB, 0 views)
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Old 11-18-2014, 11:08 AM   #7
okie-dude
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Default Re: 95 ez-go Medalist wont go

Battery voltage 37.70v

Key switch on - wht/yel - 37.18v

Red wire to solenoid - 0.00v
Green wire to limit switch(pedal box) - 0.00v

Yellow wire to solenoid - 0.00v

Green and yellow wires checked at controller box - 0.00v

I noticed on that schematic that there is a diode of some kind between the big posts on the solenoid, this solenoid doesn't have any diodes on it.
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Old 11-18-2014, 12:08 PM   #8
JohnnieB
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Default Re: 95 ez-go Medalist wont go

Sounds like there is a bad wire or connection between the keyswitch and the small post on the solenoid with three wires on it.

You have to get voltage to that post before you'll have voltage at the other places you mentioned.

--------
Originally, there was a PC board containing a resistor and a diode between the two big posts, but the PC board is typically replace with just a 250Ω resistor when it fails, so you may have just the resistor, or nothing at all.
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Old 11-18-2014, 12:38 PM   #9
okie-dude
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Default Re: 95 ez-go Medalist wont go

I have 37.18 volts to the wht/yel wire from the key switch to the small 3-wire post.

I have no power coming from the other two wires that come from the esc to the 3 wire small post.

The resistor is there it looks different then the service manual, it hangs down low and is on a little circuit board.
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Old 11-18-2014, 04:10 PM   #10
okie-dude
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Default Re: 95 ez-go Medalist wont go

Went threw the "DCS TroubleShooting Sequence"

Tested good steps 1-4

step 5 - Pin 7 - with key switch on, accelerator pedal up and F or R selected, - REF. Battery voltage.... I get battery voltage regardless if the pedal is "up" or depressed.

Step 6 - Pin 6 14-15VDC - If not replace controller.... Tested 0.00volts. So i guess, bad controller?

Step 7 - Pin 1 - .4-1.5V - If not replace ITS..... Also 0.00v, but maybe it would read 0 with a bad controller?



They pushed it back to there house after it died... I see in another post, that can fry the controller pretty fast if its not in the "tow" mode?

I hate to throw a $500 part at it and it not fix it, but the book seems to think its the controller and possible the ITS.


Where's a good place to get ez-go parts for a good price?
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