Medalist ghost

Rasor · 01-23-2020, 06:40 AM

Hi all
I have been asked to work on a 96 DCS which is doing my head in. I have re-wired from key to the controller which was originally an Alltrax NPX until I changed to a 2nd hand EZGO that I had in the shed. Everything worked well until I took it for a test drive. Went up a hill okay twice and then all of a sudden it stopped as I drove back in the shed. This has been an ongoing issue apparently. I have changed the solenoid, ITS checked the motor and it is not shorting, made sure field winding wires are connected and brushes are good. When I check pedal switch it seems okay. I have tried to jump the micro switch when it wasn’t going and sometimes it would go but mostly not. If I disconnect batteries it seems to want to work most time’s but not always.
I have suggested burning the cart or performing an excorcism as this has a ghost
Any help would be much appreciated.

handtools · 01-23-2020, 07:18 AM

Have you checked the 4 pin Molex connector between the ITS and controller? A lot of people eliminate it with butt connectors or solder and shrink wrap.

4 pin Molex.jpeg.jpg

LukeL · 01-23-2020, 08:38 AM

Quote:

Originally Posted by handtools

Have you checked the 4 pin Molex connector between the ITS and controller? A lot of people eliminate it with butt connectors or solder and shrink wrap.

Attachment 196809

X2 for this. I was thinking the same thing.

Mooncarter · 01-23-2020, 09:12 AM

If it's not already burning down there you are lucky. Good luck with it. These guys will get you going. Best wishes.

Rasor · 01-27-2020, 03:28 AM

Thanks guys
I have checked the ITS connections and all is good. I have a copy of an EZGO service manual which suggests at step 36, check voltage between Controller B+ and M-. When the cart works I get 35v however when it doesn’t it is 0v which suggest new controller. Unfortunately my customer doesn’t seem to understand that it is a new controller because he said sometimes if he rocked the cart it would work again or if he left it a while it will work. I’ve tried to explain it could thermal overload however I did thermo gun terminals and they never got over 95°F. This is really doing my head in.
All input is appreciated

01-23-2020, 06:40 AM	#1
Rasor Not Yet Wild Join Date: Sep 2012 Posts: 23	Medalist ghost Hi all I have been asked to work on a 96 DCS which is doing my head in. I have re-wired from key to the controller which was originally an Alltrax NPX until I changed to a 2nd hand EZGO that I had in the shed. Everything worked well until I took it for a test drive. Went up a hill okay twice and then all of a sudden it stopped as I drove back in the shed. This has been an ongoing issue apparently. I have changed the solenoid, ITS checked the motor and it is not shorting, made sure field winding wires are connected and brushes are good. When I check pedal switch it seems okay. I have tried to jump the micro switch when it wasn’t going and sometimes it would go but mostly not. If I disconnect batteries it seems to want to work most time’s but not always. I have suggested burning the cart or performing an excorcism as this has a ghost Any help would be much appreciated.
Rasor Not Yet Wild Join Date: Sep 2012 Posts: 23

01-23-2020, 07:18 AM	#2
handtools Gone Wild Join Date: Nov 2011 Location: S.E. Mi. Posts: 531	Re: Medalist ghost Have you checked the 4 pin Molex connector between the ITS and controller? A lot of people eliminate it with butt connectors or solder and shrink wrap. 4 pin Molex.jpeg.jpg

01-23-2020, 09:12 AM	#4
Mooncarter Gone Insane Join Date: Oct 2016 Location: Richmond, VA Posts: 14,214	Re: Medalist ghost If it's not already burning down there you are lucky. Good luck with it. These guys will get you going. Best wishes.

01-27-2020, 03:28 AM	#5
Rasor Not Yet Wild Join Date: Sep 2012 Posts: 23	Re: Medalist ghost Thanks guys I have checked the ITS connections and all is good. I have a copy of an EZGO service manual which suggests at step 36, check voltage between Controller B+ and M-. When the cart works I get 35v however when it doesn’t it is 0v which suggest new controller. Unfortunately my customer doesn’t seem to understand that it is a new controller because he said sometimes if he rocked the cart it would work again or if he left it a while it will work. I’ve tried to explain it could thermal overload however I did thermo gun terminals and they never got over 95°F. This is really doing my head in. All input is appreciated
Rasor Not Yet Wild Join Date: Sep 2012 Posts: 23

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