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Electric EZGO Electric EZ GO Marathon, Medalist, TXT and RXV. |
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01-10-2021, 11:25 PM | #1 |
Not Yet Wild
Join Date: Nov 2014
Posts: 55
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1994 has low motor voltage
I am attempting to help an elderly neighbor with her 1994 EZGO series cart. It is slow on the flats and real slow on the uphill. The six - 6 volt batteries are 18 month old Costco GC batteries.
Pack voltage after charging 38.2 v. Uphill run pack voltage 36.0 v. Uphill motor voltage (M- and B+) 19.2 v. Speed and motor voltage is about the same forward and reverse. I removed the orange wire (very faded color) from terminal on micro switch on F/R switch. This made no change in cart speed. I am not sure the orange wire was attached to MS-4 (have not removed F/R switch yet to see any label of terminal). Battery, motor, controller, and F/R switch connections are tight and clean. I have not taken all of the connections apart and shined them up. Thank you in advance for ideas on how to get this 1994 cart to go uphill a bit faster. |
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01-11-2021, 11:41 AM | #2 |
Techno-Nerd
Join Date: Jun 2011
Location: West Virginia
Posts: 19,654
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Re: 1994 has low motor voltage
Two separate issues.
1. Full pack voltage not getting to motor when pedal is floored. 2. Half speed reverse not happening. Pack voltage not getting to motor can be cable/connection issues, or solenoid contacts, or controller, or throttle. What is the voltage between the controller's B- and B+ terminals going uphill? If it is same as pack voltage, the problem is controller or throttle. If it is lower than pack voltage, then problem is cables/connections/contacts. ---------- To get half speed reverse, there has to be pack voltage on orange wire. |
01-11-2021, 06:48 PM | #3 |
Not Yet Wild
Join Date: Nov 2014
Posts: 55
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Re: 1994 has low motor voltage
Thank you JohnnieB,
Cart is fully charged .... showing 38.5 v. (with surface charge) Between B+ and B- there is 36.5 on flat driving (flat is a jogging pace) and 36.0 on uphill (uphill speed is a walking pace) 0.0 volts on what I think is the orange wire (it is faded), regardless if the old cart is sitting or driving. I sure do appreciate your coaching me through this! George |
01-11-2021, 07:10 PM | #4 | |
Techno-Nerd
Join Date: Jun 2011
Location: West Virginia
Posts: 19,654
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Re: 1994 has low motor voltage
Quote:
2. So the voltage at the controller is roughly the same as it is at the battery pack when going uphill. That means the problem is either the throttle or the controller. A 1994 would probably be a Medalist (metal) body style with a ITS type throttle and a Curtis 1206 controller, but correct me if I am wrong. Attached is how to check an ITS throttle connected to a 1206 controller. If the throttle checks out, the controller is very likely to be bad. 3. We'll troubleshoot the half speed reverse after we get the cart running normally. |
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01-12-2021, 11:24 AM | #5 |
Not Yet Wild
Join Date: Nov 2020
Posts: 21
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Re: 1994 has low motor voltage
Is this a DCS medalist cart? a picture of the controller would help the conversation.
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01-12-2021, 01:39 PM | #6 |
Techno-Nerd
Join Date: Jun 2011
Location: West Virginia
Posts: 19,654
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Re: 1994 has low motor voltage
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01-12-2021, 03:42 PM | #7 | |
Not Yet Wild
Join Date: Nov 2014
Posts: 55
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Re: 1994 has low motor voltage
Quote:
Again, this cart belongs to an 88 year old widow that lives in my 55+ community (3 miles of private roads). I am trying to get her dependable transportation again, as she no longer drives a car. Thanks again for guiding me through places I have never been before. George |
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01-12-2021, 04:23 PM | #8 |
Techno-Nerd
Join Date: Jun 2011
Location: West Virginia
Posts: 19,654
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Re: 1994 has low motor voltage
George,
There is a inline connector that connects the gray cable from the pedal box under the floor to the rest of carts wiring harness that causes lots of throttle problems. It was put there to make the cart easier to assemble at the factory and eliminating it solves the problems it can cause. Simply cut the in-line connector off and reconnect each of the four wires together with individual butt-splices or solder joints and waterproof the connections with marine grade (adhesive filled) shrink tubing. Here's a drawing showing the in-line connector and a schematic for a 94 Medalist with a series drive system |
01-12-2021, 05:12 PM | #9 |
Not Yet Wild
Join Date: Nov 2014
Posts: 55
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Re: 1994 has low motor voltage
From posting #4 from JohnnieB-----
I did 3 tests illustrated in thumbnails test 23 - key on, solenoid clicked = 0.0 v test 25 - key on, solenoid clicked = 0.0 v test 26 - key on, solenoid clicked, throttle fully depressed = 0.0 v I also opened up the throttle box under the floor mat and everything initially appears dry and clean. I did not see JohnnieB's post #9 until I returned from my neighbors. I have attached 2 pictures of the cart for your viewing pleasure. George |
01-12-2021, 06:39 PM | #10 | |
Techno-Nerd
Join Date: Jun 2011
Location: West Virginia
Posts: 19,654
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Re: 1994 has low motor voltage
Quote:
Try Pin-4 (red wire) it is in parallel with solenoid coil and should pave pack voltage on it whenever the solenoid is energized. |
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