EZGO DCS problems

[atr42flyer]

I have a 1996 EZGO DCS,

whats new,

Batteries
new solenoid
new wires
new brushes in the motor
had the controller repaired.
also upgraded to F&R hockey puck to a nice club car toggle switch.

putting this thing together tonight, It works, however I have it on jack stands to test it and when stepping on the accelerator the wheels move but they dont seem to want to go very fast. Also another problem is the wire from the the solenoid to the controller B+ is very hot I mean burn your skin hot only after a few seconds of testing.

so 2 problems

Hot *** wire B+ on the controller to solenoid

seems like its very slow. Batteries are charged.

thanks

[Sir Nuke]

FIRST off.....whatever you do. do NOT free wheel (run up the speed) your cart on jack stands....its a sure fired way to either burn up your motor or even have it come apart on you.

[mutant]

look for the wires where turn the corner at the back of the battery box to rub through-that can ground there...

[JohnnieB]

Both symptoms may be caused by the same problem.

If the cable from controller's B- terminal to battery pack's main B- terminal isn't getting hot also, the cable from the solenoid's controller side large terminal to the controller's B+ terming most likely has excessive resistance.

Since it takes a lot of electrical energy to get that cable hot quickly and the energy being converted to heat is not getting to the motor, so the motor runs slowly.

You stated you have new wires (cables), so reinstall the original cable and see what happens.

Of course the problem could be the stud on the solenoid or controller, but the most likely suspect is a poorly constructed new cable.

[atr42flyer]

Originally Posted by JohnnieB

Both symptoms may be caused by the same problem.

If the cable from controller's B- terminal to battery pack's main B- terminal isn't getting hot also, the cable from the solenoid's controller side large terminal to the controller's B+ terming most likely has excessive resistance.

Since it takes a lot of electrical energy to get that cable hot quickly and the energy being converted to heat is not getting to the motor, so the motor runs slowly.

You stated you have new wires (cables), so reinstall the original cable and see what happens.

Of course the problem could be the stud on the solenoid or controller, but the most likely suspect is a poorly constructed new cable.

There is also between the main lugs of the solenoid I bought a new resistor? Or something like that it has a small circuit board and two resistor like round things. Is it possible that it is installed backwards? I followed the wiring diagram and installed it the way I thought it came off.

[atr42flyer]

Wiuldninstalling the pre charge resistor the wrong way cause this?

[scottyb]

Remove the smaller solenoid diode and try the cart. Heat problem solved?
Post pic of the solenoid install.

[yamahaguy97]

Originally Posted by mutant

look for the wires where turn the corner at the back of the battery box to rub through-that can ground there...

May not be related to the issue but good point about the rubbing through the insulation on the battery tray. I have not seen it cause an issue too many times but it does definitely happen

[atr42flyer]

Originally Posted by scottyb

Remove the smaller solenoid diode and try the cart. Heat problem solved?
Post pic of the solenoid install.

Scotty,
I was hoping you would respond.

It is a 1996 Ezgo TXT DCS, It didn't have a diode between the two small terminals on the old solenoid.

But I did buy a brand new recharge resistor https://diygolfcart.com/solenoid-res...CABEgJRrfD_BwE

The controller popped last night. So I need to send it back for repair. (again)

on a DCS cart is the smaller diode required? I did not see one on the wiring diagram.
I will try and upload a pic of the solenoid later

[mutant]

put an alltrax in it...