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Old 07-26-2011, 08:33 PM   #1
10tontractor
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Default 1996 medalist trouble #959182

1996 ezgo Medalist non dcs and pds (no tour or tow switch)

Ran great last time parked. Charged up overnight. Went to use it, turned key, rev switch on.. cart grinded backwards (solenoid clicking) no go. Same thing fwd. Now not even that except solenoid clicking.

We have trouble shot , batteries, wires to motor, solenoid replaced (thought it was this first) getting good reading everwhere except no power is getting to motor. Have followed other trouble shooting ideas.
Motor test ok.

Appears we have a short occuring somewhere? Any guesses here ?

Still looking for a wiring chart for this cart.
Is there a wiring chart for the non-dcs /pds unit allready posted here for '96 medalist?

How do I check out the speed contoller on this unit?
Appears voltage is stopping transfer of current to motor there.
Is this a common replacement part?

Thanks, Jack

Last edited by 10tontractor; 07-26-2011 at 09:02 PM.. Reason: added info
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Old 07-26-2011, 09:00 PM   #2
scottyb
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Default Re: 1996 medalist trouble #959182

Welcome to bgw!

Solenoid clicking is a the sound of it making/breaking contact rapidly... usually caused by low voltage or bad connection that won't hold the current.

95% of the time a battery has a cell that is dropping out under load... connect your DVM to the pack and try to go...... what is the voltage before and after you push the gas?
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Old 07-26-2011, 09:01 PM   #3
10tontractor
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Default Re: 1996 medalist trouble #959182

How do I check out the speed contoller on this unit?
Appears voltage is stopping transfer of current to motor there.
Is this a common replacement part?
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Old 07-27-2011, 07:43 AM   #4
Marsharo
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Default Re: 1996 medalist trouble #959182

Follow Scotty's recomendation and get the readings for him. There are quite a few that can and will answer your issue if you give them the info they need. Remember electricity can be tricky and since they are not standing there you have to be there eyes and hands to help you resolve your problem.
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Old 07-27-2011, 08:30 AM   #5
madoc1
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Default Re: 1996 medalist trouble #959182

do as scotty says and check the batts. here is your wiring , thx. to scotty.

welcome to BGW.
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File Type: jpg scottys wiring.jpg (154.8 KB, 11 views)
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Old 07-27-2011, 03:43 PM   #6
10tontractor
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Default Re: 1996 medalist trouble #959182

Quote:
Originally Posted by madoc1 View Post
do as scotty says and check the batts. here is your wiring , thx. to scotty.

welcome to BGW.
Thanks, Jim
Now we can trouble shoot in the light.

Dis what Scotty said. No trouble there. Now thinking I have a speed control issue.

Thanks, Jack
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Old 07-27-2011, 05:15 PM   #7
10tontractor
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Default Re: 1996 medalist trouble #959182

1996 EZGO Medalist Series cart 36volt

Start Battery voltage: 34.5 All batteries ck out fine and all cells have good specificity rates.


Step 1

Switch cart to "Tow-maintenance" mode by flipping the switch under seat. Disconnect the black battery cable (negative) from the battery, open the cover to the speed controller and then reconnect the negative battery cable.
* NO Tow/maint switch on mine
Step 1
Inspect all wires to ensure that they are attached and well connected, there are no breaks, corrosion or interference with the wires. Take the reading of the battery voltage by connecting the positive and negative probes to the battery. Write the voltage reading down.
Voltage is 34.5
(I've not had on charger for 10 days as that was last use.)

Step 2
Test the solenoid to see if this is the problem. Place the positive probe on the solenoid post that is closest to the battery. The reading should be equal to battery's voltage. If not, there is a wiring issue in the solenoid. Connect the positive probe to the other post and take a reading. If the voltage is not at least three volts fewer than the voltage reading for the battery, the resistor must be replaced. If you have a volt reading equal to the battery volts, the solenoid is the issue.
* Solenoid and resister were replaced.

*Voltage test to r/s solenoid post (near batteries) reads 34.4 other side reads 34.4 *not 3volts less then*

Step 3
Check the power output from the controller by connecting the negative probe to the controller's M terminal and positive to the B+ terminal. Press the accelerator and watch to see if the voltage increases. It should increase from a reading of 0 to the full voltage of the battery. If the motor is not turning, the problem may be in the directional switch or motor. The controller is bad and must be replaced if there is no voltage.

Did this test. When I placed (-) probe on M and pos probe on B+ term it reads 32.8 v.. pushing the pedal down then 'does nothing' as no change in volts remained at 32.8. Turn key on same.. But when I did test by placing F/R switch either way.. O reading.

Using these test results, can anyone advise or lend some advice here? Anymore test I can try?
Thanks, Jack

Last edited by 10tontractor; 07-27-2011 at 05:20 PM.. Reason: update
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Old 07-27-2011, 06:55 PM   #8
10tontractor
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Default Re: 1996 medalist trouble #959182

Quote:
Originally Posted by scottyb View Post
Welcome to bgw!

Solenoid clicking is a the sound of it making/breaking contact rapidly... usually caused by low voltage or bad connection that won't hold the current.

95% of the time a battery has a cell that is dropping out under load... connect your DVM to the pack and try to go...... what is the voltage before and after you push the gas?
WOW ! I got issues! 34.5 volts on battery pack. With key on and F/R on fwd.. Volt read out goes from 34.5 all the way down to 2.5 v (yes 2.5 volts)

What now ??
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Old 07-27-2011, 09:44 PM   #9
rabbitreborn
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Default Re: 1996 medalist trouble #959182

replace your battery pack
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