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



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Old 01-24-2013, 02:36 AM   #1
schuetzb001
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Default Works fine off the ground !

Just got this 1996, that was inop, installed new batteries, new cables, has new controller, new solenoid, with the wheels off the ground it seems to run fine, once its on the ground it tries to move For / Rev but won't ! All tests from batteries, thru solenoid to controller are good, also the motor looks new!did notice the diode/ resistor was on backwards after getting a nice spark putting the neg battery cable on & also have 36 + volts at the B+ terminal on the controller before the soleniod clicks on, not so with the resistor off the solenoid ? would that effect the controller or is the new controller bad ? Thanks for any help !
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Old 01-24-2013, 02:38 AM   #2
schuetzb001
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Default Re: Works fine off the ground !

Forgot, this is a EZ-GO, with DSC, Thanks
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Old 01-24-2013, 06:35 AM   #3
JohnnieB
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Default Re: Works fine off the ground !

Welcome to BGW!

Sounds like you have a 1996 DCS cart.

What is the actual battery pack voltage? (36+ volts is only about 50% charged. 38.2V is fully charged)

Even if it is only 36V, it should move when wheels are on ground, so:
1. The controller isn't turning on all the way.
2. Full power isn't getting to the motor.
3. The controller isn't being told to turn fully on.
4. The motor is bad.
5. The cart doesn't roll freely.

You mention the cable were replaced. All 10 of them?
Also, the two smaller cable from F1 & F2 terminals to F1 & F2 on motor (Might be labeled S1 & S2 on motor) might be damaged. Check them for worn through insulation where they are routed around battery frame.

Get the batteries fully charged and then check the voltage between A1 and A2 terminals on motor.
Voltage should be about Zero when solenoid first clicks and then climb to full battery pack voltage as pedal is pressed to floor.

Also, Check voltage between F1 & F2 on motor.
Should be about 8.0V with pedal on floor.


Let us know what you find and we'll go from there.
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Old 01-24-2013, 04:58 PM   #4
schuetzb001
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Default Re: Works fine off the ground !

Ok I have 38.4 Volts across the Batteries, at A1 to A2 with pedal fully depressed I get only 5 Volts, S1 / S2 its zero volts, check the cables and see no problems.
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Old 01-24-2013, 05:09 PM   #5
scottyb
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Default Re: Works fine off the ground !

When the cart is on the ground, does the pack voltage drop when you try to go? If so, to what?
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Old 01-24-2013, 06:11 PM   #6
schuetzb001
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Default Re: Works fine off the ground !

Yes pack voltage drops to 35.2 Volts
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Old 01-25-2013, 05:59 AM   #7
JohnnieB
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Default Re: Works fine off the ground !

Sound like you might have more than one problem.

The battery pack dropping from 38.4V at rest to 35.2V under load indicates the current flow is about 1/3 of their Amp-Hour ratting (C/3 discharge).
Is anything getting hot???

What are the individual battery voltages under load???
At 35.2V they should all read 5.87V +/- 0.1V. If not, the batteries reading a lot lower than the rest are sick.
---------------

With pedal on floor, the voltage between A1&A2 ought to be pack voltage (35.2V ???) and there ought to be some voltage between S1&S2.
Having only 5V between A1&A2 indicates the controller isn't being told to turn on fully (ITS issues) or is being told to turn on fully and isn't(Controller issues).
Check the voltage at Pin-2 (Black wire) on controller. It should be between 14.0V and 16.0V.
Check voltage at Pin-1 (White wire) on controller. It should be from 0.45V to 0.53V when solenoid first clicks and go to at least 1.5V when pedal is on floor.
--------------

You mentioned the motor looked new. What is the part number on the label???
It might be the wrong type motor. (IE: A Series wound motor in a Sepex Motor system)
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Old 01-25-2013, 01:10 PM   #8
schuetzb001
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Default Re: Works fine off the ground !

All 6 batteries hold around 6V under load, the ITS seems fine, 14.7 V @ Pin 2 & .46 to !.6 @ Pin 1, the controller & cables to motor are heating up under a load, the motor is a Advance Pt# 7122 / ES1 4002, Rating AU2500 5-17-12,the only thing I noticed is I have battery voltage @ pin 5 before the solenid energizes which per the sequence test I should not have until the solenid is closed ?wish I had another controller to swap but do not, would hate to spend $350 for a new one if I don't need it
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Old 01-25-2013, 01:39 PM   #9
schuetzb001
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Default Re: Works fine off the ground !

Just Double check voltages 2 motor, 5 Volts @ A1/A2 with pedal to floor, 0 Volts @ S1/S2 with pedal to floor & cables attached, with cables off I get Batt Volts between S1/S2 cables & 0 Volts between A1/A2 cable ends
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Old 01-25-2013, 01:50 PM   #10
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Default Re: Works fine off the ground !

Quote:
Originally Posted by schuetzb001 View Post
1. All 6 batteries hold around 6V under load,

2. the ITS seems fine, 14.7 V @ Pin 2 & .46 to !.6 @ Pin 1,

3. the controller & cables to motor are heating up under a load,

4. the motor is a Advance Pt# 7122 / ES1 4002, Rating AU2500 5-17-12,

5. the only thing I noticed is I have battery voltage @ pin 5 before the solenid energizes which per the sequence test I should not have until the solenid is closed

6. ?wish I had another controller to swap but do not, would hate to spend $350 for a new one if I don't need it
1. Good news.
2. If !.6V is a typo for 1.6V, good news.
3. Tells me there is a lot of current flowing. Matches up with 1&2 above
4. Ouch!!!!!!!!!!!!! here is what I get when search that part number:
Motor, AMD (Series), 36-volt
(4-hp@4400 rpm) (ES1-4002)
Motor, AMD high speed, series motor. 36-volt (4-hp@4400 rpm) with 19 spline coupler. For Columbia and Melex with Dana axle, E-Z-GO 1988-up series cars, Yamaha G14, G16. Speeds up to 20 mph with stock controller. Also works on 48-volt. Not for use on PDS or DCS cars. Same as D297.


Having a Series wound motor and a Sepex controller explains the strange voltage readings.

5. B+ on Pin-5 is what tell the controller to activate the solenoid. (It comes from pedal microswitch)
I'd check the wiring to be sure it is correct.

6. Hopefully, the controller/motor mismatch didn't blow the controller, but if it did, replace it with an Altrax DCX400(DCS)
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