1991 X-440, 444, 444J, 444F Won't Go

[busterkrazmoe]

My 92 year-old neighbor has one of the above EZGO models in his garage. He said he changed batteries in it about four years ago and then it wouldn't work. I assume he means it doesn't drive. My suspicion is he probably didn't attach the batteries correctly. I have the service manual and will check the wiring and voltage first. Yesterday when he was showing the cart to me, he plugged in the charging cable, turned on the ignition and put it in reverse and the alert warning worked. So that's a good thing based upon my limited knowledge base.

Handwritten on the service manual is 685059 E0692. I'm assuming this is serial number and will look on the plate this weekend.

The manual doesn't have a troubleshooting chapter. I searched this forum and couldn't find a sticky Tutorial to help me diagnose why the cart doesn't go. Can someone please direct me to any Tutorial in case I overlooked it? If there isn't any tutorial, can someone offer suggestions on what to check?

Thanks.

[Bama Brad]

First thing is to make sure batteries are charged and still good. Here is manual JohnnieB posted some years ago. Maybe he will see you post soon and give advice
89-91 electic and gas parts.pdf

[JohnnieB]

First, we need to figure out which drive system the cart has, resistor or controller.

as for the body style The X-440 is a three wheeler, the X-444 is a four wheeler. The F suffix is for lights. Don't know what a J suffix is for.

Pictures under the seat will help identify the drive type.

[busterkrazmoe]

Originally Posted by Bama Brad

First thing is to make sure batteries are charged and still good. Here is manual JohnnieB posted some years ago. Maybe he will see you post soon and give advice
Attachment 219207

Thanks for the manual. It will be invaluable to me as I take on this project.

[busterkrazmoe]

Originally Posted by JohnnieB

First, we need to figure out which drive system the cart has, resistor or controller.

as for the body style The X-440 is a three wheeler, the X-444 is a four wheeler. The F suffix is for lights. Don't know what a J suffix is for.

Pictures under the seat will help identify the drive type.

It must be an X-444F because it has headlights. I'll upload a photo of the drive asap. I found a Polaroid in the manual but it's faded after 30 years. I'll know more maybe after the weekend. Thanks

[busterkrazmoe]

Originally Posted by JohnnieB

First, we need to figure out which drive system the cart has, resistor or controller.

as for the body style The X-440 is a three wheeler, the X-444 is a four wheeler. The F suffix is for lights. Don't know what a J suffix is for.

Pictures under the seat will help identify the drive type.

It's a X-444J (Spirit).
Here are some pictures.
https://photos.app.goo.gl/4xdtHu2zU2g3qGsn9

Hopefully they will help you help me.

My neighbor said that one day he came back from playing golf and parked the cart. A few hours later he was going to drive the cart to the post office but it wouldn't start. The reverse alert works. I didn't try the lights or horn.

I hoping some one can walk be through the troubleshooting process. There is a fly in the ointment and that is the battery charger is not working. I suspect that may limit troubleshooting. I will post that issue in another post.

[busterkrazmoe]

Originally Posted by JohnnieB

First, we need to figure out which drive system the cart has, resistor or controller.

Pictures under the seat will help identify the drive type.

Please see attached

[JohnnieB]

The 9 year old batteries are waving a red flag.

What is the battery pack voltage and what are the individual battery voltages?

[JohnnieB]

There are three threads about this cart. One about the cart not running, one about the charger not working and one about a melted battery terminal, which is why neither the cart nor the charger works.

The batteries have a 4/12 sticker on them, so the are 9 years old, which is about twice the normal lifespan for cart batteries and the cables are corroded withing the conductors.

Replace the batteries and the cables, then the cart and charger will probably work.

BTW: The melted battery terminal is most likely due to over-tightening the wingnut. Torque spec is 95 to 105 In/Lb (7.9 to 8.75 Ft/Lb) and is easy to exceed.

The stud is actually a stainless steel bolt with the hex head embedded in lead. Too much torque applied and the head twists inside the soft lead, then only the six points of the hex head make contact and the current density skyrockets, causing a lot of heat.

[busterkrazmoe]

The EZGO service tech came to the golf shop to service the fleet and I towed the cart down to have the tech give me an estimate on how much this "free" cart would cost me.

He was in agreement with you that the batteries and cables need to be replaced. Unfortunately, he didn't have a 36 volt pack with him to test the rest of the cart. On his next visit, he will bring one and jack the cart up and see if it runs okay.

He noticed a wire that was not hooked up and he thinks it is for an accessory. See attachment of the wire terminal by the black plastic cover of the control module.

Initially in this post I said the cart was a 1991 model but I was wrong. The i.d. tag tells me it's a 1992. And the model is a Freedom. In one of my other posts, I asked help in finding a wiring diagram for the cart. Unfortunately, the link I was given went only to 1991.

I have the User's manual and service guide but it only has the battery replacement wiring guide. I've searched for a 1992 EZGO 444F Freedom diagram but couldn't locate it. There is a manual for sale on eBay but I thought I would check this forum out first before pulling the trigger and spending a whole $5. Can you or someone lead me to one? Or will the 1991 diagram be good enough?

Thanks in advance.