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Electric EZGO Electric EZ GO Marathon, Medalist, TXT and RXV. |
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04-21-2015, 01:33 PM | #11 | |
Not Yet Wild
Join Date: Jun 2014
Posts: 6
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Re: 2005 EZGO TXT Repair / Upgrade Project - Thoughts on Controller Options / General
Quote:
you got me thinking, so I re-ran some tests. The #'s I posted yesterday are from a few days back. Here are some fresh stats. Our Pin 4 started fluctuating again in voltage, then miraculously held steady @ reference voltage. I walked away, came back an hour later and still the same readings. I did go through the line to jiggle connections (with the exception of getting behind the key to check things out). The other day, I was getting voltage fluctuation in Pin 4, the wheels would move slightly then shutter, then higher voltage spikes would move them more, then no movement, yet voltage fluctuation still present. Now I've got reference voltage, and absolutely no wheel movement, so go figure :). Stats are attached below, am I'm curious to see if you still think it's a wiring problem, stock controller problem, or maybe a mixture of both or even ITS related. I still have not inspected the Pedal Box yet, but plan to do so here this afternoon. Your tech genius is appreciated. |
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04-22-2015, 07:46 AM | #12 | |
Techno-Nerd
Join Date: Jun 2011
Location: West Virginia
Posts: 19,654
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Re: 2005 EZGO TXT Repair / Upgrade Project - Thoughts on Controller Options / General
Quote:
As for thinking it is a wiring problem, I'm a troubleshooter, not a guesser. If something is being told to do something and it isn't, it is bad, but the controller wasn't getting full pack voltage on Pin-4, so it might not be being told to pass amps to the motor. Low voltage on Pin-4 is an identifiable issue that needs to be corrected. The new voltage data provided identified another voltage issue that is very likely to be a wiring issue. B+ to M- should read Zero volts when the solenoid clicks and increase to near full pack voltage as the pedal is pushed to the floor. B- to M- is the reciprocal. It should read full pack voltage when the solenoid clicks and decrease to near Zero as the pedal is pushed to floor. The B- to M- voltage reading when the pedal is up indicates something is amiss in the high current cables, their connections, high current contacts in the F/R assembly or the motor. That is another identifiable issue that needs to be corrected. The Pin-2 voltage isn't right (Ought to be 9.0v - 11.5V for a Curtis 1206 series controller) but the voltage at Pin-1 is varying as it should, if you have a Curtis 1206 controller, so it may or may not be an issue. |
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04-23-2015, 06:09 PM | #13 | |
Not Yet Wild
Join Date: Jun 2014
Posts: 6
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Re: 2005 EZGO TXT Repair / Upgrade Project - Thoughts on Controller Options / General
Quote:
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04-24-2015, 07:21 AM | #14 | |
Techno-Nerd
Join Date: Jun 2011
Location: West Virginia
Posts: 19,654
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Re: 2005 EZGO TXT Repair / Upgrade Project - Thoughts on Controller Options / General
Quote:
The next place to check is the in-line connector shown in your picture. I had that connector fail when I was out in the middle of nowhere. Fortunately, I had a pair of nail clippers with me. |
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04-29-2015, 06:16 PM | #15 | |
Not Yet Wild
Join Date: Jun 2014
Posts: 6
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Re: 2005 EZGO TXT Repair / Upgrade Project - Thoughts on Controller Options / General
Quote:
Post 1 Day Charge @ rest: 38.4 – Pack Voltage 38.4 - Battery B- to Bat Side Solenoid 37.8 - Battery B- to Contr Side Solenoid 37.8 - Battery B- to Contr B+ 37.8 - Contr B- to Contr B+ Solenoid Engages = YES Now after testing simple motor function etc., the Pack Ref Voltage Dropped to about 38.0 to 38.1 sustained, so I proceeding troubleshooting Pin4 voltage issue I was having previously. Now prior to charge, I did conclude Continuity on the following: Solenoid Charger Wires Red Wire from Reed Switch Bypass Connection Points @ Charger & Key switch connection MS-2 F/R & MS / Pedal Box Pedal Box Black to Control Harness Black Pedal Box White to Control Harness White So JohnnieB, your comment of “if something is being told to do something and it isn't, it is bad” was digging into my soul (By the way, JohnnieB, I used that line in a meeting earlier this week so thanks for that phrase of simple yet foundational logic). Now back to the Pin4 voltage issue. I measured out @ 37.8V from Battery B- to Pin 4 with Solenoid Engaged So I decided to trace this along the path I’m assuming this was the correct way to go. With the Solenoid engaged, Bat B- to the following : Positive Terminal, White Charger Positive Pin, Red Reed Bypass Ring Terminal, Red Connector, MS F/R Red Terminal, MS F/R Blue Terminal, Green Key Switch Wire, Key Switch Terminal Blue, Pedal Box MS Green Terminal, & Pedal Box MS Red Terminal All Came in @ 37.8V along the line. Now here is where I had an “ahaa” moment digesting your comment. When Pedal was fully engaged, Voltage was still fluctuating @ Pin4, just like previous measurements last week before my recent charge. Values were between 35.4V & 36V. The same fluctuation was also occurring at all measurement points in the line. Hmmmm.. So maybe all points in the line are “Not being told what to do because of a bad battery cell perhaps? Not sure, and I’m no battery expert. I’m attaching Battery Stats in the below Grid (also note my reference voltage did drop when I performed this test). What do you think? Battery # 1 & # 3 are looking suspect? Or is this normal? At this point I’m beginning to think my pack has been the root cause all along. What are your thoughts on this latest data set and my above observations? I feel like I know way more about this cart now then 3 weeks ago. Am I on the right troubleshooting track here? |
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Tags |
cables, controller problem, ezgo 2005, troubleshoot help. |
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