No Buzzer, randomly moves, very slow start when it does move

[Ratnic]

I am new to the forum, and have been reading a lot of threads about carts with the same problem as mine. But there is something different with my issues.

The Cart is:
EZ-Go Textron
Serial No.: 914488
Manfac No.: 19L88

It is a DCS with the "Run/Tow" switch under the seat. The cart was purchased by my father years ago, and has sat in a barn for about 5 years now. I am trying to get it back in working order.

The original charger was rusted out and falling apart. So I bought a new one.

The batteries have just been replaced. They were all dead, no water. Tried to revive them with water and charging but a few would not get up to charge so I just replaced them. I bought the Sams energizers, please do not scold me, I wanted the better batteries, but want to get this thing working before I start putting a lot of dollars into it. Next set of batteries when I have to replace them will be the better brands.

After replacing the batteries and charging them the cart would move great, but when I would stop the cart it would not start back up sometimes. I would get out and push it while stepping on the pedal, and slowly it would get up to speed and take off. This happened a lot in the grass, short 2-3 inch grass. The cart has stock tires. My dad only used it for golfing. But a few times it would not do anything no matter what I did. In fact the last time it failed I basically waited about 30 minutes, then walked out to try it again, and it started right up. I drove that thing to the garage and parked it. During that failure, and with it in "Run", it was very hard to push. I do not know if it was because of the grass or the motor locking up.

In reverse the cart would take off faster than in forward. The buzzer has never come on. During the failures reverse would do the same thing as forward.

Now the cart (when it does move) starts out real slow, then works up to speed in about 2-3 seconds. It does not lurch forward like it used to do.
I have made sure the batteries are charged by keeping the charger on it the last day or so. But it just slowly starts out when it moves.

I have gone over the connections and everything is tight. I replaced all the battery cables with new bigger #4 AWG when I replaced the batteries.

Any suggestions on where I should start? Should I go through the DCS troubleshooting? I have a background in electrical, just do not know where to start. Thanks.

-Ratnic

[JohnnieB]

Welcome to BGW.
I can't help you much because I'm not familiar with DCS carts, but maybe someone that is will chime in.

Perhaps the following will be useful.

Here is what the EZGO lookup site returns for your serial number: Model Year: 1995 Make/Model: Medalist or TXT (DCS)

If it has a metal body it is a Medalist.
If it has a plastic body it is a TXT.

A DCS cart has regenerative braking, so it would push hard in the "Run" mode. That is one of the reasons for the Run/Tow switch.
To be pulled or pushed, it has to be in the "Tow" position, or there is a good chance of ruining the controller.

DCS controllers are hyper-sensitive to low voltage, so if you operated, or tried to operate, the cart with low battery voltage, there is a possibility the controller was damaged.

You've got new batteries, so they need to be broken-in to get full capacity.
Here is how to do that:
http://www.cartsunlimited.net/Batter...n_Methods.html

If you haven't already, check out the STICKY:'s at the top of the Electric EZGO forum. (one menu level up from where you are now). The top one has a schematic and troubleshooting info.

Sorry I couldn't be of more help.

[Ratnic]

I will read what you suggested.
I installed the new batteries, charged them, but did not think there was more to do.
But I will read the battery document to learn more about what I do not know...I do not know.

The cart was pushed about 100 ft. from the barn to where I loaded it up when the Batteries were old and none useful. I hope I did not ruin the controller.

Thanks...

-Ratnic

[JohnnieB]

I forgot to mention. If you connected up the new batteries while the Run/Tow switch was in Run, you might have also damaged the controller.

Whenever you connect or disconnect a battery cable, you've got to put the Run/Tow switch in the Tow position. In fact it is a good idea to put it into Tow when you do any work on the cart unless you're doing something that actually requires the controller to be powered up.

The DCS controller was a high failure item, which is why EZGO replaced it with the PDS design, which still has some issues, but a little more forgiving.

A way to check for mechanical drag is to put the switch in Tow, sit on the cart and place your hand on the ground.
On a smooth, level surface, you should be able to push cart with just the one hand on the ground.

After sitting for 5 years, you might have wheel bearings with dried out grease, brake shoes dragging, or parking brake not fully releasing due to gummed up brake cables and similar stuff.

If you break those deep cycle Energizers in properly, keep them as fully charged as possible or practical, keep the terminals clean & tight (about 100 in/lb - don't over-tighten) and water them regularly (Distilled water only and don't overfill), they'll last several years. Maybe not as long and maybe they won't have as much performance as the top line batteries, but they didn't cost as much.

If it turns out to be a bad controller, look into an aftermarket replacement for the DCS controller. There are several that work a lot better than a DCS ever will.

[yurtle]

Originally Posted by Ratnic

The cart was pushed about 100 ft. from the barn to where I loaded it up when the Batteries were old and none useful. I hope I did not ruin the controller.

Thanks...

-Ratnic

Was the Run/Tow switch in Tow when you pushed it?

[Ratnic]

I had the Run/Tow switch in Run. I was trying to "push start it". Which is what I did to get it moving on earlier failures. Stand on the pedal and try pushing it forward.

The solenoid clicks when you press the pedal. I will try to see if anything like the brakes are binding stopping it from moving forward. That is what it sounds like and feels like. Because once it is going, it goes.

I am sure there are a lot more things wrong than just this. This just happens to be the most visible problem. From sitting around these many years it will be a chore.

Tomorrow I will lift it up and get under and around the brakes to check things out, see what could be binding or not moving. Do not really know what to look at. So this ought to be fun.

Thanks...
-Ratnic

[scottyb]

It sounds like controller failure to me except for the part that if you push i far enough it will go???? Otherwise its textbook DCS controller failure, not uncommon in a cart with bad batteries.
We use a DCS cart on the ranch and it runs circles around just about anything else.... just a bit quirky, I guess.

[cbordea]

mine is a 91 and it seems sometimes after a stop I have to press the pedal an extra time or two to get it going again.
I've figured out that the pedal isn't coming all the way back up and you can tell it is still very slightly still wanting to go. If I pull the pedal all the way back up it seems to work ok.
It might not be related at all, i think your cart is different technology than mine but check to make sure the pedal is coming all the way back up and good luck.