92 ezgo wont go

[puddlejumper92]

Recently was given a 92 ezgo with a 36 volt system. Replaced solenoid, and cart wont go. I press the gas pedal and the motor barely turns for a second then stops and won't go again, the solenoid clicks but no go. Need a little insight if it could be a bad controller or what. I've checked all connections and wiring but motor won't go.

[JohnnieB]

First thing to check is the power source.

What is the battery voltage about 12 hours after the charger shuts off?
Should be 38.2V for the 36V pack. 6.37V for each 6V battery and all six should be within 0.1V of each other.

[puddlejumper92]

I was getting 38.2v, I've gone over most of the system with my meter and all my signs say I should be running but it doesnt. Maybe loose connection of some sort inside controller?

[JohnnieB]

Does the solenoid click when pedal is pushed?

If so, connect your DVM between the M- and B- terminals on controller
Lift rear tires off ground and put on jackstands so the half ton cart doesn't take off unexpectedly and run over somebody or something.

Press pedal just far enough for solenoid to click.
You should measure full pack voltage.

If so, press pedal to floor.
The voltage should decrease to near Zero.

[puddlejumper92]

Had full voltage when barely pressed, but voltage did not drop when pedal fully pressed.

[JohnnieB]

Originally Posted by puddlejumper92

Had full voltage when barely pressed, but voltage did not drop when pedal fully pressed.

Could be a bad controller, or it could be a bad throttle signal to the controller.

Pull the Black wire and White wire from the throttle pot-box, off the top of the controller and measure between the wires with an Ohmmeter.
Should be about 0Ω with pedal up and about 5,000Ω with pedal down.

[puddlejumper92]

I'm getting 5000 ohms. It's just weird how one time I can press the pedal and it'll run fine but then the next time I get nothing. I wonder if it's a loose connection inside the controller or something

[JohnnieB]

Originally Posted by puddlejumper92

I'm getting 5000 ohms. It's just weird how one time I can press the pedal and it'll run fine but then the next time I get nothing. I wonder if it's a loose connection inside the controller or something

Intermittent problems are difficult to troubleshoot since the only time you can troubleshoot them is while the cart is misbehaving.

Basically, you have to wait until if fails and then make some voltage measurements and observations.

Here is a schematic for your cart (I think).

I'd check the Blue wire form the pedal switch (MS-3) first.

[puddlejumper92]

Last night I was reading voltage at m- and b- on the controller and the first time I did it the voltage dropped from 38 down to almost 0 then I did it again and my voltage didn't drop.

[JohnnieB]

Okay, either the controller is not passing amps to the motor when it is being told to do so, or it isn't being told to do so, or it isn't powered-up.

Pack voltage on the Blue wire powers up the controller, so when the voltage between B- and M- doesn't drop, check for pack voltage on the Blue wire. (Just move the test probe from M- to the Blue wire terminal.)

If the controller is being powered-up, pull the Black and White wire from the Pot-box (throttle) and clip a 500Ω (or thereabouts) resistor between the terminals they came off of.

That should give the controller a continuous 1/10th throttle signal, so it may jerk a bit when the solenoid clicks.