Motor Problem EZGO Series Cart

[rbuggies48IN]

Friend's cart Motor has had the A1 stud repaired externally by welding a nut to this threaded connection. The connection is now not tight to the housing and rotates a little, which I believe is causing the cart to 'cut-out' when it hits a bump. Question: Is this an easy fix if I have the motor rebuilt for more speed and torque or is it something I could do just this repair on if I pull the motor down to replace this 'bad' stud at A1? What would the estimated cost to have this stud fixed by others or the estimated cost of DIY parts? Also, what parts does this fix entail?

[JohnnieB]

It depends on which series motor is installed in your friend's cart.

With some of them, the stud is part of the replacement brush set: https://shop.ezgo.com/products/Brush...ement-Kit.html

If that is the brush set needed, you can probably find it at one of the BGW site sponsors for less than what EZGO sells them.

Plum Quick (http://www.plumquick.com/)does the Bandit upgrade for about $225.

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The motor needs to be fixed, but the drop out may due to a loose control wiring or reed switch.

[rbuggies48IN]

Thanks Johnnieb!! I am supposed to get to this on Monday. I will let you know what we find!

[rbuggies48IN]

Johnnieb. We found the micro switches on the FNR had all lost their plastic supports. We fixed this, but no change. We checked the micro switches themselves and they are good. Cart runs great under no load with wheels on jack stands, but under load (on the ground the problem is worse). We will check the possibility of rear break drum wear on axle spline and then check into motor. Any other thoughts? Thanks again for your help on this.

[rbuggies48IN]

Appears we also had a 'bad/burnt' connection at motor. Working on fix now.

[rbuggies48IN]

Replaced the loose connector at A2, but cart still 'kicks-out'/jerks during operation. Controller, ITS, or ???

[JohnnieB]

In the first post in this thread, you said you thought a loose stud on motor was causing the cart to "cut-out" when it hits a bump. After fixing , does the cart still run normally on a smooth surface and cut-out on a bumpy surface?

Is the solenoid dropping out or is it staying energized?

If the solenoid is staying energized, monitor the voltage between the main + & - terminals on the battery pack while driving.

It'll bounce around some because pack voltage drops someplace around 1V to 2V per 100A of current being drawn from the batteries, but shouldn't drop below about 32V unless you are trying to tow your garage up a hill.

If that is okay, monitor between the B- and B+ terminals on the controller while driving. You should get very close to the same readings that you got at the battery pack.

If it is, monitor the voltage between M- and B+ on controller while driving with pedal on the floor. You should read pretty close to the same as you got in the previous two tests.

NOTE: The cart has to "cut-out" while these voltages are being monitored or the tests won't tell us anything.

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You say the cart runs fine with rear tires off ground, but misbehaves when the cart is driven. Try applying the brakes a little while tires are off the ground to simulate the mechanical load of the cart being driven.

[rbuggies48IN]

Johnnieb

Thank you for staying with me on this. I will back working on the cart tomorrow afternoon and should be posting results no later than Thursday.

[rbuggies48IN]

Finally got to this project. To make a long project story short, the problem was a loose wire connection tucked up behind the cart's existing slide drawer for coins and drink holder. Controller checked out fine.