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



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Old 01-10-2021, 11:25 PM   #1
gruelens
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Default 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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Old 01-11-2021, 11:41 AM   #2
JohnnieB
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Default 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.
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Old 01-11-2021, 06:48 PM   #3
gruelens
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Default 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
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Old 01-11-2021, 07:10 PM   #4
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Default Re: 1994 has low motor voltage

Quote:
Originally Posted by gruelens View Post
Thank you JohnnieB,

1. Cart is fully charged .... showing 38.5 v. (with surface charge)

2. 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)

3. 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
1. I don't know where you are located, but it's winter, so it's cooler and battery capacity decreases as the temperature drops. However, the batteries look okay so far.

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.
Attached Images
File Type: jpg ITS Voltage - 1.jpg (47.7 KB, 0 views)
File Type: jpg ITS Voltage - 2.jpg (48.2 KB, 0 views)
File Type: jpg ITS Voltage - 3.jpg (44.2 KB, 0 views)
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Old 01-12-2021, 11:24 AM   #5
Kyle263611
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Default 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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Old 01-12-2021, 01:39 PM   #6
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Default Re: 1994 has low motor voltage

Quote:
Originally Posted by Kyle263611 View Post
Is this a DCS medalist cart? a picture of the controller would help the conversation.
It was identified as a "1994 EZGO series cart" in the first line of the first post in this thread.
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Old 01-12-2021, 03:42 PM   #7
gruelens
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Default Re: 1994 has low motor voltage

Quote:
Originally Posted by Kyle263611 View Post
Is this a DCS medalist cart? a picture of the controller would help the conversation.
It is a 1994 EZGO Medalist (metal body panels). It has a 1206 controller with 4 main terminals. I presume it is an ITS throttle control, I will be doing the checks JohnnieB prescribed, in posting 4, later today. The batteries are 1.5 years old and seem to be doing fine (southern California with warm daytime temps).

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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Old 01-12-2021, 04:23 PM   #8
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Default 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
Attached Images
File Type: jpg Medalist ITS Box parts Pg-1.JPG (49.7 KB, 0 views)
File Type: jpg 949536v.jpg (59.2 KB, 0 views)
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Old 01-12-2021, 05:12 PM   #9
gruelens
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Default 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
Attached Images
File Type: jpg controller.jpg (196.9 KB, 0 views)
File Type: jpg throttle box.jpg (185.1 KB, 0 views)
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Old 01-12-2021, 06:39 PM   #10
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Default Re: 1994 has low motor voltage

Quote:
Originally Posted by gruelens View Post
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
There ought to be some voltage on those pins, or the cart wouldn't move at all. Sure your getting the test probe far enough into the backside of the molex connector?

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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