EZGO Cart charge does not last long

[cgtech]

Originally Posted by JohnnieB

It'll most likely pass a diode and continuity checks anyway, original complaint was the cart ran for about 2 miles and then started loosing power and then quit.

Has six new Rolls brand 6V-215AH batteries.

I think you're right, but this was the only "bench test" I know of.

[JohnnieB]

Originally Posted by cgtech

I think you're right, but this was the only "bench test" I know of.

I found this ages ago in a Curtis 1204/5 manual and it could be expanded upon to do sepex controllers, but you more or less have to recreate the cart on the bench, so why not just use the cart.

[djcvet]

I did some additional troubleshooting. I made sure the batteries were fully charged and I hooked up my Multimeter to the batteries. I started out at 38.9 volts and observed the voltage as I drove the cart. It never got below 35.9 volts even at full throttle. I drove around our block at least 5 times with everything normal. Then all of a sudden it slowed and then stopped dead. Voltage was at 37.8 but no action from the accelerator. I could here the solenoid click when I pushed on the accelerator and also when I let up. I'm going to let it set where it died and wait awhile and then go back to see what it does. Very frustrating.

[Mooncarter]

I would voltage test each battery and see what you have.

[ThreeCW]

Any excessive temperatures from any of the components?

It will be interesting to see if your cart works again once it cools down. Just brain storming here ... could the controller be shutting down due to excessive temperature.

I did a simple test on my cart a few weeks ago ... after pulling a heavy load slowly up a 1/2 mile gravel road hill at approximately 200 to 250 amp draw, I temperature checked (by feeling with my hand ... I did not have my infrared thermometer with me) and checked each battery cable, each battery connection, all cables and connection of the high amp circuit, circuit breaker, solenoid, Fwd Rev contactor, controller and motor for excessive temperatures. All cables and connections were not much above ambient temperature (a good sign), the motor was warm to the touch but I could hold my hand on it comfortably and the controller was very warm ... too hot to hold onto for more that 3 seconds. Not a very scientific test but it did give me reassurance that there were not any problems lurking.

You might want to try a similar test on your cart ... use an infrared thermometer if you have one ... if not, your hand will guide you too to see if anything jumps out why your cart is shutting down.

[cgtech]

Originally Posted by JohnnieB

I found this ages ago in a Curtis 1204/5 manual and it could be expanded upon to do sepex controllers, but you more or less have to recreate the cart on the bench, so why not just use the cart.

That's pretty interesting, and funny that curtis would suggest that. It wouldnt fool any of the more modern controllers that look for tach sensor signals & such.

[JohnnieB]

Originally Posted by djcvet

I did some additional troubleshooting. I made sure the batteries were fully charged and I hooked up my Multimeter to the batteries. I started out at 38.9 volts and observed the voltage as I drove the cart. It never got below 35.9 volts even at full throttle. I drove around our block at least 5 times with everything normal. Then all of a sudden it slowed and then stopped dead. Voltage was at 37.8 but no action from the accelerator. I could here the solenoid click when I pushed on the accelerator and also when I let up. I'm going to let it set where it died and wait awhile and then go back to see what it does. Very frustrating.

Since the batteries appear to be okay, chances are high the controller is failing.

Here are a couple troubleshooting procedures that should be done immediately after the cart fails.

[djcvet]

Does anyone know if Amazon sells the 9 pin connector controller for the 1996 36 volt DCR cart? If not, is there any company that sells exchange controllers?

[djcvet]

The controller for my cart (1996 EZGO 36 volt DCR with 9 pin connector) seems to be very hard to find. Is there another part number controller that will work in place of this one?

[JohnnieB]

Originally Posted by djcvet

The controller for my cart (1996 EZGO 36 volt DCR with 9 pin connector) seems to be very hard to find. Is there another part number controller that will work in place of this one?

It is hard to find because it was a poor design that failed often and EZGO replaced the DCS drive system with the PDS drive system after about 5 years of production.

Alltrax made a Plug-n-Play replacement called the DCX that eliminated the DCS controller's shortcomings, but that is no longer available either. The current replacement is a Alltrax XCT48x00-DCS. (The "x" is for 3, 4 or 5 to designate a 300A, 400A or 500A controller)