96 EZGO won't move....sometimes

[JohnnieB]

SWMBO (She Who Must Be Obeyed) took me out for a late lunch at my favorite restaurant for my birthday while I took her to the same place at the same time for Valentine's Day.


I forgot the "Quick Test" procedure on page F-6 existed, it leaves out a lot of important details.

When I said troubleshooting tree, I was referring to the "Detailed Troubleshooting Diagram" starting on page F-9.

If you are getting 37.5V between the main positive and main negative terminals on the battery pack, you should get 37.5V between the B- and B+ terminals on the controller when the Run/Tow switch is in Run and the F/R selector is in either F or R, the keyswitch is ON and the pedal pushed.

If not, what are the voltages on Pins 5, 6, 7, 9 and 10?

[hoggjaww]

Originally Posted by JohnnieB

SWMBO (She Who Must Be Obeyed) took me out for a late lunch at my favorite restaurant for my birthday while I took her to the same place at the same time for Valentine's Day.


I forgot the "Quick Test" procedure on page F-6 existed, it leaves out a lot of important details.

When I said troubleshooting tree, I was referring to the "Detailed Troubleshooting Diagram" starting on page F-9.

If you are getting 37.5V between the main positive and main negative terminals on the battery pack, you should get 37.5V between the B- and B+ terminals on the controller when the Run/Tow switch is in Run and the F/R selector is in either F or R, the keyswitch is ON and the pedal pushed.

If not, what are the voltages on Pins 5, 6, 7, 9 and 10?

5.0v until I press the pedal then it goes down to .1 and stays there, release pedal .1, put the F&R in neutral in returns to 5.0v.

As for the second test, in Run with key off and key on same results.

Ground on pack, testing with red lead.

pin 5____0.0

pin 6____7.0

pin 7____7.0

pin 9____37.2

pin 10___37.2

[JohnnieB]

Originally Posted by hoggjaww

<Snip> Extraneous information.

Ground on pack, testing with red lead.

1. pin 5____0.0

2. pin 6____7.0

3. pin 7____7.0

4. pin 9____37.2

5. pin 10___37.2

1. Should be full pack voltage (37.5V) when pedal is pushed.

2. Should be full pack voltage (37.5V) when in Run/Tow = Run, Key = ON and a direction is selected.

3. Should be full pack voltage (37.5V) when in Run/Tow = Run, Key = ON, a direction is selected and Pedal IS NOT pushed, Drops to 0V when pedal is pushed.

4. & 5. Both OK. (Should be full pack voltage (37.5V) when in Run/Tow = Run.)

The voltage on Pin-6 is extremely low, so controller is not being powered up. Check the voltage on the smaller of the three wires coming out of the back of the charge receptacle (Reed switch),

Voltage path from source to Pin-6 highlighted on attached schematic.

[hoggjaww]

Originally Posted by JohnnieB

1. Should be full pack voltage (37.5V) when pedal is pushed.

2. Should be full pack voltage (37.5V) when in Run/Tow = Run, Key = ON and a direction is selected.

3. Should be full pack voltage (37.5V) when in Run/Tow = Run, Key = ON, a direction is selected and Pedal IS NOT pushed, Drops to 0V when pedal is pushed.

4. & 5. Both OK. (Should be full pack voltage (37.5V) when in Run/Tow = Run.)

The voltage on Pin-6 is extremely low, so controller is not being powered up. Check the voltage on the smaller of the three wires coming out of the back of the charge receptacle (Reed switch),

Voltage path from source to Pin-6 highlighted on attached schematic.

Pin 5 is 4.6 key off,F&R neutral, pedal pushed.
It reads 36.5v key on, in gear, pedal pushed.

Pins 6 & 7 tested just as you said it should

Pack voltage coming of reed switch wire. (already jumped)

I guess I'll pull the batteries and take them in for a proper load test.

[scottyb]

Originally Posted by hoggjaww

Pin 5 is 4.6 key off,F&R neutral, pedal pushed.
It reads 36.5v key on, in gear, pedal pushed.

Pins 6 & 7 tested just as you said it should

Pack voltage coming of reed switch wire. (already jumped)

I guess I'll pull the batteries and take them in for a proper load test.

Actually they are already in the best load test machine = the golf cart. Few test facilities have 350 amp load testers. Simply voltage test if trouble shooting and monitor pack voltage while testing to insure pack voltage drop (6v+) is not a factor. Once running do the same test for true under load tests. In dash digital battery meter will make this task very convenient.

[hoggjaww]

Well they all passed a load test at 400 cca just took a guess on that. Trojan T-105s.
What is next solenoid?

[scottyb]

Solenoid? Does it click when you try to go?

[hoggjaww]

Originally Posted by scottyb

Solenoid? Does it click when you try to go?

Yes, and the cart will sometimes move 3 or 4 feet.

[scottyb]

sometimes? test the solenoid when the cart is not going as asked.
Is there 36v between the 2 small solenoid posts? Yes? Is there 36v on both big posts with the solenoid resistor removed and controller to solenoid cable removed?

[hoggjaww]

Right now I put it in F, press the pedal, hear the click, won't move. Wait a few seconds and press the pedal again no click and it still won't move.

Shift FR switch to N and hear a less pronounced click, then move FR switch to R and again hear a click and cart won't move.