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Old 01-14-2017, 10:13 AM   #11
Cape Fear Scot
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Default Re: 2002 cart wiring questions

Thanks handtools. I didn't know if the Series Drive and DCS motors were different, or if the difference was in the "brain" only.
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Old 01-14-2017, 10:40 AM   #12
JohnnieB
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Default Re: 2002 cart wiring questions

Quote:
Originally Posted by Cape Fear Scot View Post
Got this 2002 cart going, but it seems to be at 75% power and speed. This is a good set of batteries, fully charged. They were kicking the other cart along at a good pace. This 2002 cart was out in the weather and hadn't run in several years, so I initially attributed the sluggishness to "setting up" (as we say here in the South) and the cold weather. However, it's 75 degrees today, and the speed/power isn't appreciably better. I cleaned all the battery cable connections except the ones on the motor (harder to get to). Any other suggestions?

I'm considering pulling the motor out of the other cart and installing it in this one. Is there any reason that a '98 EZGO motor won't fit a 2002?
The motor out of the 98 will fit mechanically, but won't work electrically because it is a SepEX (SEParately EXcited) motor, while the 02 is a Series (Series wound) motor. In a Series motor the same high current that passes through the armature windings also passes through the field (stator) windings ans in a SepEx motor high current only passes through the armature while a separate low current passes through the field. If the rear wheels of the 02 were off the ground, the 98 motor connect as a Series motor might turn them slowly, but it won't move the cart.

It is the battery temperature rather than air temperature that determines temperature related battery performance and the batteries have a huge thermal mass, so their temperature was closer to whatever the previous night's temperature was than what the next day's temperature is.

What is the voltage between the battery pack's main negative and main positive terminals while the cart is running on level ground at top speed?

What is the voltage between the controller's B- and B+ terminals when running at tops speed over the same stretch of level ground?

What is the voltage between the controller's M- and B+ terminals when running at tops speed with pedal on floor over the same stretch of level ground?
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Old 01-14-2017, 10:51 AM   #13
JohnnieB
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Default Re: 2002 cart wiring questions

Quote:
Originally Posted by handtools View Post
"I don't understand why the backup warning beeper comes on when the key switch circuit isn't closed. Is that supposed to happen? Or has someone bypassed the key switch?"

On my '94 series drive cart the reverse beeper works when in reverse whether the key is on or off. Also the speed difference you notice is probably the series drive vs DCS, which I believe will also keep you from switching motors.
Unless the reed switch has been bypassed, the reverse beeper will sound anytime the direction selector lever is in Reverse and the charger isn't plugged into cart.

In their stock form, the top speeds of 98 DCS and a 02 Series would be about the same, but the series cart would have more low end torque than the DCS.
Attached Images
File Type: jpg Wiring Diagram - Series - Beeper traced.JPG (58.8 KB, 0 views)
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Old 01-14-2017, 11:11 AM   #14
nickajack
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Default Re: 2002 cart wiring questions

I'm also puzzled because I don't see a connector for a run/tow switch. I could install the housing and switch off my '98, but I don't see where to plug the switch in. I downloaded a 2002 service manual, and it does show a switch.


Where did you download that service manual from? I need a wiring diagram for a EZ 2+2 Shuttle (2000 model) series wired. If you can post that or PM it to me that would be great!! Basically what I need is the power circuit wiring ie: Wires from motor to FNR and to Solenoid and Controller.
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Old 01-14-2017, 11:21 AM   #15
nickajack
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Default Re: 2002 cart wiring questions

Nevermind....I see JohnnieB posted one. It might be the same one I recently downloaded from another thread though,...which was the wrong one, but maybe I can figure it out from this one. Thank anyway.
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Old 01-14-2017, 11:46 AM   #16
JohnnieB
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Default Re: 2002 cart wiring questions

Quote:
Originally Posted by nickajack View Post
I'm also puzzled because I don't see a connector for a run/tow switch. I could install the housing and switch off my '98, but I don't see where to plug the switch in. I downloaded a 2002 service manual, and it does show a switch.


Where did you download that service manual from? I need a wiring diagram for a EZ 2+2 Shuttle (2000 model) series wired. If you can post that or PM it to me that would be great!! Basically what I need is the power circuit wiring ie: Wires from motor to FNR and to Solenoid and Controller.
The thing to remember is that there are three types of drive system found in golf carts, Series, SepEx and AC. EZGO has only produced carts with AC drives since 2008, so we will stick with the two DC types that existed prior to 2008.

SepEx drive carts (DCS, PDS and TXT48.) have a Run/Tow switch, Series drive carts do not have a Run/Tow switch. See attached Drive ID chart.

A SepEX controller will not run a Series motor and Series controller will not run a SepEx motor. In addition there is an incompatible difference in the high current cables. A Series drive uses 13 heavy gauge cables while a SepEx drive only needs 10 of them.

In a nutshell, the motor type, controller type and high current cabling have to match.

Attached is a service manual for a 2+2. The series drive is referred to as a "Non-DCS" and is in Section-E.
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