94 Electric EZGO Won't Go. Where to start with diagnosis?

[fire4034]

My 1994 Ezgo has been running fine. It recently stopped while riding in it, and I assumed batteries were dead. After charging, it will not run.

I checked batteries, and each of the 6 has over 6V, and the entire Pack reads 36V.

I get reverse sound, but will not move. I lifted rear end with jack, but still no movement. I get a click from the solenoid when accelerator is pressed.

I assume I need to check solenoid, speed control, and motor??

Not sure where to start with further diagnosis. I have speed controller cover removed and access to the controller and solenoid.

Any further help would be appreciated.

Thanks, Frank

[glavini]

Hey Frank, read through my post titled blinking voltmeter and other things. You could probably go off that if you have the same series cart that I do.

[fire4034]

well the silenoid has 38 volts to the small lead with the red wires when the acclelerator is pushed. Also have continuity to the small lead with black wires on other side of resistor on front of sillenoid.

What is the next thing to check? Speed controller?

Thanks, Frank

[fire4034]

OK so as I followed the recommendations about checking speed controller, I listed my results here. I am not sure what voltages I need on each pin.

Based on the image below of my connector, the volt readings are as follows.

Wires at plastic connector on top of speed controller.

Red Wire 38.2 volts when pedal is pushed

Orange Wire 0 volts when pedal is pushed

Black Wire 13.9 when pedal is pushed

White Wire 1.4 volts when pedal is pushed down all the way, this number seems to be smaller like 0.7 when pedal is pushed half way down (if this matters)?

Any help from this point would be great.

Thanks, Frank

[radioman]

Are you sure the motor is not turning? I am not sure why you would get a varying voltage on the speed sensor lead unless is the motor is turning. Just my thoughts.

[fire4034]

I have it up on jack and wheels don't spin at all.

Frank

[radioman]

I was just thinking you might have a drive train problem. The motor may be spinning but not driving the wheels. If you rotate one rear wheel does the other one turn? Just guessing. You going to have to wait on someone else to help you. In the meantime study some of the wiring diagrams of different models in the stickies section. When the solenoid is energized and the pedal depressed check for B+ on both of the big lugs to be sure the contacts are good.

[JohnnieB]

Originally Posted by fire4034

OK so as I followed the recommendations about checking speed controller, I listed my results here. I am not sure what voltages I need on each pin.

Based on the image below of my connector, the volt readings are as follows.

Wires at plastic connector on top of speed controller.

Red Wire 38.2 volts when pedal is pushed Normal

Orange Wire 0 volts when pedal is pushed Normal if in F, this is the 1/2 speed reverse signal line

Black Wire 13.9 when pedal is pushed Part of ITS - High, but probably not root cause.

White Wire 1.4 volts when pedal is pushed down all the way, this number seems to be smaller like 0.7 when pedal is pushed half way down (if this matters)? Part of ITS - Slightly low at WOT, but probably not root cause.


Any help from this point would be great.

Thanks, Frank

Try reducing the size of the picture so it can be seen on the screen.

Measure between B- and M- terminals with your DVM.
Should measure FULL battery pack voltage when pedal is pressed just far enough for solenoid to click.
Should decrease to near zero and pedal is pressed to floor.

Tell use what you get.

[radioman]

JohnnieB comes highly recommended to help you troubleshoot. A great reservoir of experience and information.

[fire4034]

Thanks so much for the help. I will change the picture asap. As for the test you requested here is the info. Also when I look at drawings I measured the two black wires farthest to the right going into top of speed control? I have 4 large terminals on top of controller and these are the two that seem to be B- and M-?

Battery Pack 36v

When on the B- and M- connections I also get 36v

When I press the accelerator to point where Silenoid clicks I get a drop to 0 but it seems that meter jumps around from 0-4v. Then as I push accelerator all the way down, I get to zero. As I let accelerator up volts slowly climb back up to 36v.