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



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Old 09-25-2015, 08:53 PM   #1
49ford
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Default 96 no go

I have a 96 ezgo non dcs I haven't been able to get to run yet. I have checked many things on this cart and am using the Ezgo factory manual to trouble shoot it.
I have new batteries, a "good used" controller, a new ITS, all the micro switches work, tested continuity on control wires.
I'm at the point where, if you jump battery voltage across the solenoid, the cart runs in forward and reverse, and speeds up and slows down with the foot throttle. Without the jumper there is nothing.
I keep stopping in the diagnostic tree at the ITS. I had two used ones, and bought a new one and they all fail the test the same way. They show 13.8v when they should be 14-15, and when the 4pin connnector is disconnected the voltage goes to 14.1v.
Has anyone ever ran into this ?
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Old 09-25-2015, 09:24 PM   #2
crash test dummy
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Default Re: 96 no go

tested the solenoid ?
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Old 09-25-2015, 10:40 PM   #3
scottyb
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Default Re: 96 no go

Test the solenoid activation circuit 2
There should be 36v at both ends of every red line when the key on, in gear, pedal down.
Attached Images
File Type: jpg Ezgo Series solenoid activation diagram.jpg (107.9 KB, 0 views)
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Old 09-26-2015, 07:42 AM   #4
49ford
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Default Re: 96 no go

I thought I had tested the solenoid out on the bench. Anyhow, I printed out the diagram, and going to the shop for a while.
Thanks guys
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Old 09-26-2015, 09:57 AM   #5
radioman
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Default Re: 96 no go

Does the solenoid click when you press the pedal? A good place to test the solenoid is in the cart that won't move and a good place to start basic troubleshooting by making some simple voltage tests before you tear the cart apart. Guessing what the problem may be using a helter-skelter approach replacing components first can cost $'s, waste time and not fix problem.
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Old 09-26-2015, 10:26 AM   #6
radioman
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Default Re: 96 no go

Quote:
Originally Posted by 49ford View Post
I have a 96 ezgo non dcs I haven't been able to get to run yet. I have checked many things on this cart and am using the Ezgo factory manual to trouble shoot it.
I have new batteries, a "good used" controller, a new ITS, all the micro switches work, tested continuity on control wires.
I'm at the point where, if you jump battery voltage across the solenoid, the cart runs in forward and reverse, and speeds up and slows down with the foot throttle. Without the jumper there is nothing.
I keep stopping in the diagnostic tree at the ITS. I had two used ones, and bought a new one and they all fail the test the same way. They show 13.8v when they should be 14-15, and when the 4pin connnector is disconnected the voltage goes to 14.1v.
Has anyone ever ran into this ?
Problem is not likely the ITS if the cart responds to the pedal with the solenoid contacts jumped. Those troubleshooting charts are confusing. While you are in the pedal box it might be a good idea to double check the micro switch proper adjustment and it is the correct contact arrangement. It should be a normally closed contacts and held open by the plunger and close (normal) when the plunger moves as the pedal is depressed and the switch lever cam drops off the plunger.
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Old 09-26-2015, 02:54 PM   #7
49ford
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Default Re: 96 no go

Thanks again for pointing me in the right direction. With the diagram above in hand, I discovered there was no wire from B+ to neutral microswitch. Huh!
Put a wire in, cleaned cart off to test run, and still wouldn't run. After another hour I found a intermittent connection on the 4pin connector to ITS. Wired around that plug and the cart runs! Whew! Now I'm wondering how many parts I had on the cart that were good parts that got swapped out.
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