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Electric EZGO Electric EZ GO Marathon, Medalist, TXT and RXV.



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Old 02-23-2018, 10:45 AM   #1
markm
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Angry EZGO series cart issues - won't move

I am stumped on this cart.

Date code is F1904 (old EZGO serial number lookup link is no longer valid and new link only shows 2007 and newer)

Battery pack voltage 37.55v

New solenoid and it clicks so not low voltage issue

New f/r Switch old was burnt

Controller out of working cart

Motor out of working cart

Cart will not move

I have tested the B- and M- at controller. 36.87 and push pedal voltage goes to 37.51


What am I missing?
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Old 02-23-2018, 10:50 AM   #2
scottyb
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Default Re: EZGO series cart issues - won't move

Controller is not letting current pass.
Maybe no Power to controller circuit board or no throttle signal?
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Old 02-23-2018, 11:02 AM   #3
markm
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Default Re: EZGO series cart issues - won't move

What is the best way to test those two things?
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Old 02-23-2018, 11:14 AM   #4
JohnnieB
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Default Re: EZGO series cart issues - won't move

Controller powering up: Measure voltage on Pin-4. Ought to go to battery pack voltage when pedal is pushed.

Throttle: See attached.
Attached Images
File Type: jpg ITS Voltage - 1.jpg (47.7 KB, 0 views)
File Type: jpg ITS Voltage - 2.jpg (48.2 KB, 0 views)
File Type: jpg ITS Voltage - 3.jpg (44.2 KB, 0 views)
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Old 02-23-2018, 11:40 AM   #5
markm
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Default Re: EZGO series cart issues - won't move

Controller powering up = battery pack voltage CHECK

#23 voltage was 14.40
#25 voltage was 13.65
#26 voltage was 13.65
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Old 02-23-2018, 04:44 PM   #6
markm
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Default Re: EZGO series cart issues - won't move

So what does that tell me that the throttle circuit is messed up somewhere?
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Old 02-23-2018, 04:48 PM   #7
JohnnieB
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Default Re: EZGO series cart issues - won't move

Looks like the four pin in-line connector between pedal box and cart's wiring harness has some issues. Possibly the black wire is picking up some voltage from the green wire.

Clean connector, or cut it off and connect the wires directly with butt splices or solder joints. Weather proof the joints with shrink tubing.
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Old 02-23-2018, 04:54 PM   #8
JohnnieB
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Default Re: EZGO series cart issues - won't move

Quote:
Originally Posted by markm View Post
So what does that tell me that the throttle circuit is messed up somewhere?
Yes.

The controller is the voltage source for the ITS sensor in the pedal box, so the higher than normal reading means bad controller or bad ITS sensor circuit. The odds of having two bad controllers, one of which is known to work in a different cart, is pretty high, so that leaves the ITS sensor and wiring. Crosstalk in the in-line connector is a common problem since the connector is exposed to water and mud kicked up by the tires.
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Old 02-23-2018, 05:06 PM   #9
markm
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Default Re: EZGO series cart issues - won't move

Thank you Johnnie I will dig around with that wiring after I finish this build.
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Old 02-23-2018, 05:23 PM   #10
jayp1017
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Default Re: EZGO series cart issues - won't move

I'm not sure what the IPS sensor is but I'm thinking its what I know as the POT box or the accelerator switch.

From personal experience I had the same issue in different carts.

I found it to be the brushes in the motor once ($100 very easy to do) and in another cart it was the forward/reverse switch contact board.

The copper contact bolts were burned but that really wasn't the issue...
the issue lies in the contact board being burned/melted so much that the copper contact was recessed into the board and not perfectly flat with the wiper contacts of the actual switch.

I got lucky and just wrapped the shaft of the copper contactor bolt close to the head with some electrical tape (or it may have been foil) to build a backer which fill the irregularity of the contactor hole...stuck it back in the board so it was perfectly level ...worked for me and it was free.
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