cart won't run

[g.mussell]

Hi guys new member here, so please excuse any breeches of etiquette. I have an ezgo pds about 2004. It quit on me. I have tried to go through the flo chart in the manuel. I have replaced the motor, the its sensor, and last month I replaced the controller(after that it worked fine for a few weeks). When you hit the gas pedal, the tires rotate about 20 degrees and then nothing. I am having trouble getting through the flo chart. There is a square that says
"voltage between Battery B- and Controller side of solenoid."
Then
"1.0-5.0 less than reference voltage?"

the two responces are yes, and No(same)

My problem is that my reading is about 10 volts less than reference voltage. So I don't know what to do next?

thanks
George

I forgot to mention, it does not give me any trouble codes.

[yamahaguy97]

Originally Posted by g.mussell

Hi guys new member here, so please excuse any breeches of etiquette. I have an ezgo pds about 2004. It quit on me. I have tried to go through the flo chart in the manuel. I have replaced the motor, the its sensor, and last month I replaced the controller(after that it worked fine for a few weeks). When you hit the gas pedal, the tires rotate about 20 degrees and then nothing. I am having trouble getting through the flo chart. There is a square that says
"voltage between Battery B- and Controller side of solenoid."
Then
"1.0-5.0 less than reference voltage?"

the two responces are yes, and No(same)

My problem is that my reading is about 10 volts less than reference voltage. So I don't know what to do next?

thanks
George

I forgot to mention, it does not give me any trouble codes.

hello,

may be asking a dumb question here but how are your batteries and how old are they? i just have to ask because its a common issue when people least expect it

steve

[g.mussell]

2 years old. they read about 37.6 when I test them.

[JohnnieB]

At 37.6V, your batteries are only about 80% charged and the plates are sulfating as we speak. Put them on charge.
Attached is a SoC chart for Trojan batteries.

The 10V drop is troubling. What you are measuring is the voltage drop across the resistor connected between the solenoid's two large terminals. Its purpose is the keep the filter capacitors inside the controller charged so the solenoid contacts don't arc as much when the close. Normally, this requires from about 4ma to 20ma of current (1.0V to 5.0V across 250Ω), but it appears that your controller (or something) is drawing about 40ma, or the resistance it is passing through is greater than 250Ω.

Could be some bad high current cables. Connect the negative test lead to the B- terminal on the controller and check the voltage on both of the solenoid's large terminals sequentially. What is the controller side voltage and what is the battery side voltage?

Setting that aside, does the solenoid click when you push the pedal and the cart moves or twitches?

FWIW: I have seen better troubleshooting trees than those printed in EZGO manuals, but the information they provide is pretty good.

[g.mussell]

Thanks. I have it at the house, have been working on it for a couple of weeks so the batteries are drained I brought the charger home yesterday so they should be fully charged tomorrow . When I check the two terminals on the celinoid, where should the run/tow mode, key and direction selector switches be?

Thanks
george

[JohnnieB]

It doesn't matter how the switches are set for this test, but for most voltage measurements they should be set as if you were going to be driving the cart.

[g.mussell]

Thanks today was our club championship so I was busy all day but I hope to try it tomorrow

Thanks
George

[g.mussell]

The solenoid clicks
Reference voltage 38.1
Controller b- battery side of solenoid 38.1
Controller b- controllers side of solenoid 12.2

Thanks
George

[g.mussell]

I reread the post and tried it again this time with key on and run tow switch to run and then
Controler b- to controllers side of solenoid was 37.5

[g.mussell]

I'm just trying bump my post. I hope I can get this problem worked out tomorrow.

thanks

George