2004 Elec Ezgo PDS Won't move

[mdavey]

Hi, I have a 2004 EZGO PDS electric golf cart. The other day it just stopped moving. You can press the accelerator down, to no avail.

I replaced the solenoid, as the old one was not clicking when engaging the accelerator. Now it clicks, but no movement.

The batteries show 42.1v (36v system). The battery side of the solenoid shows 42.1v and the other side shows 41.5. I tested the controller on the voltage meter with neg on M1 and Pos on B+. Without the pedal engaged, it shows about 35 volts. Once the pedal is engaged, it shows 42.1v for a few seconds, then drops back down to about 35v.

If you can point me in the right direction here on how to diagnose this, it would be appreciated.

Thanks in advance for your help!

[JohnnieB]

Welcome to BGW!

If the solenoid clicks when pedal is pushed, connect your DVM between the B- and A1 terminals on the controller.

Push pedal just far enough for solenoid to click and you should read FULL battery pack voltage.
If so, push pedal slowly to floor and voltage should smoothly decrease to zero.

Let us know what you get.

[mdavey]

Thanks for the help JohnnieB!

So, with B- and A1 terminals on the controller, I get 6.4v DC to start. Once the pedal is slightly pressed (solenoid clicks), it goes to 1.2v DC and as the pedal is press more to the floor, it goes to zero. Then it returns back to 6.5v DC after the pedal is released.

[JohnnieB]

You have an open, or more correctly - very high resistance, some where in the high current loop.

You get pack voltage when you measure between the main positive and main negative terminals on the battery pack, so the problem is one of the cables highlighted in Red or Blue, or their connections, or the motor (Armature/Brushes)

[mdavey]

Thanks JohnnieB, you're awesome!!!

I will check the cables and connections that you have highlighted. We did hear an intermittent grinding sound coming from the back when driving up hill, a few weeks prior to the issue. It's good to be able to rule out the controller.

Thanks again, you have been a huge help!

[mdavey]

So, I checked all the wires you high lighted, everything looks good. I guess the next step is to rebuild or replace the motor. Are these motors worth rebuilding or would you recommend just replacing them. Also is there anyone you would recommend buying one through?

Thanks again JohnnieB!

[Great white north]

Check the resistor across the solenoid , remove it and see if it moves

[JohnnieB]

Rebuild or Replace? That depends on what you plan to do with the cart.

For a rebuild with some performance tweaking, send the motor to Plum Quick: http://www.plumquick.com/

For a replacement I prefer D&D: http://www.ddmotorsystems.com/

The trick is to plan ahead and repair/replace things that fail now with the stuff that you think you will be happy with in the future.