power at half with new batteries

[robpertz]

2006 ezgo 36V, just installed new Trojan 105's. 1st run out, everything was normal. Drove to 75% and charged overnight. Hopped on this morning, cart feels like half power. Used DVM, all batteries are reading over 6V. All cables are new. Removed access cover and wire brushed all connections, nuts and washers. Cart still only feels like its got half power. Controller was rebuilt last year. Nothing else has been changed. Any ideas? Thanks!

[yurtle]

Just a guess, but on the FNR there is a 1/2 speed microswitch for reverse. It could be stuck closed. Simply remove the 1/2 speed wire from the controller to test, if you don't have a meter to test this.

[robpertz]

Turned out to be the positive wire on the solenoid mounted to the controller was burnt. I cut out the burnt section, works fine. Should I be looking at replacing the solenoid ?

[yurtle]

I wouldn't think so. A solenoid is simply an on/off switch. It can fail, but if a cable was partially melted, it may have limited current. Was it burned close enough to the solenoid to cause physical damage? Visible? If not, it's probably fine. Check ALL cables for damage, since they are all the same age and have probably been maintained (or abused) the same.

[robpertz]

It was a 16 awg wire, burned right next to the terminal mount. There was no visible damage to the solenoid, but once I removed the controller cover it smelled like burnt electrical. Let it be? Thanks for your help!!

[yurtle]

There are two circuits in a buggy. One that carries small current, in what I call wires. The second takes higher current to the motor through what I call cables. I assumed you were talking about the latter. Wires rarely fail, unless there is corrosion or physical damage. Since your failure was in a wire, I can't understand how you were only getting 1/2 power, then by fixing the wire, the problem was solved. Remote control troubleshooting is often difficult. However, it appears your controller, throttle, and solenoid are working, so you may be fine. I'd drive limited distances for a few days, in case you need to tow it home. Even the smaller wires can smell if their insulation fails and they "burn", though usually it's the cables that cause problems.

I'd still inspect all wires and cables for nicked insulation or corrosion.

[yurtle]

Also, unplug the plug at the controller and use contact cleaner, replug/unplug/replug a few time, since it also smelled at the controller.

[robpertz]

Yea, I don't get it either. That's what I was looking for, a cable damaged somewhere, not a wire. I will definitely take your advice and recheck all connections. Thank you for your help! Much appreciated !!