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Old 01-29-2021, 04:58 PM   #1
CWGrisw0ld
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Default Ezgo Roypow fail

Flew out to my dad’s to install a 56ah Roypow pack in his 2015 Ezgo TXT. I had installed one in my CC Onward and it was a breeze so I figured this would be no sweat. Got battery mounted, turned on and found it only had a bar of charge. We went ahead and plugged in the new included charger and initially everything seemed fine. After 3 minutes, smoke started coming from charging point, we unplugged and battery started beeping and shut itself off.

We checked in the morning and couldn’t see any obvious damage. We plugged charger back in and this time, no smoke and battery charged to full. Went to test the cart and nothing. No reverse buzzer, no solenoid click when pressing the pedal. Tested voltage at the battery and it’s fine. Replaced the solenoid and ignition switch so far and still can’t get the solenoid to click.

Any ideas?
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Old 01-29-2021, 05:05 PM   #2
fstop
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Default Re: Ezgo Roypow fail

Quote:
Originally Posted by CWGrisw0ld View Post
Flew out to my dad’s to install a 56ah Roypow pack in his 2015 Ezgo TXT. I had installed one in my CC Onward and it was a breeze so I figured this would be no sweat. Got battery mounted, turned on and found it only had a bar of charge. We went ahead and plugged in the new included charger and initially everything seemed fine. After 3 minutes, smoke started coming from charging point, we unplugged and battery started beeping and shut itself off.

We checked in the morning and couldn’t see any obvious damage. We plugged charger back in and this time, no smoke and battery charged to full. Went to test the cart and nothing. No reverse buzzer, no solenoid click when pressing the pedal. Tested voltage at the battery and it’s fine. Replaced the solenoid and ignition switch so far and still can’t get the solenoid to click.

Any ideas?
Check the controller? - don't know if EzGo has a fuse inline with it (hope so in this case) or what though. Maybe ask on EzGo forum as well.
Good luck with it - hope it is something minor.
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Old 01-29-2021, 05:58 PM   #3
CWGrisw0ld
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Default Re: Ezgo Roypow fail

Thanks for the response! Tested controller and appears to be working. If I apply positive to the small terminal on the solenoid, cart will go. So something upstream of the solenoid is fried.
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Old 01-30-2021, 07:07 AM   #4
fstop
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Default Re: Ezgo Roypow fail

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Originally Posted by CWGrisw0ld View Post
Thanks for the response! Tested controller and appears to be working. If I apply positive to the small terminal on the solenoid, cart will go. So something upstream of the solenoid is fried.
Not sure I completely understand the situation but I think the controller should be supplying that voltage to the solenoid coil.

Maybe the throttle somehow got fried? I'm not up on how ezgo does things though - if it was a cc that could at least be a possibility.
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Old 01-30-2021, 08:10 AM   #5
handtools
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Default Re: Ezgo Roypow fail

I think I would start by checking the micro switch in the pedal box.
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Old 01-30-2021, 10:31 AM   #6
fstop
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Default Re: Ezgo Roypow fail

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I think I would start by checking the micro switch in the pedal box.
Yes, good advice - sounds like it is a similar setup to CC, where the micro-switch is part of the throttle position sensor assembly.
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Old 03-02-2021, 12:36 PM   #7
CWGrisw0ld
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Default Re: Ezgo Roypow fail

If anyone reads this in the future with a similar issue - it turns out that one of the pins on the Run/Tow switch wiring harness was burned up. Continuity across the switch was fine, but cart ran when I bypassed it. Looking carefully at the harness, one of the pins was bit blackened, so I bypassed the harness and soldered the wires together. So far, so good!
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Old 03-02-2021, 03:12 PM   #8
Bama Brad
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Default Re: Ezgo Roypow fail

So, this incident had nothing to do with the Roypow? Just happened to fail when you installed the new Roypow? Am I interpreting that correctly?
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Old 03-02-2021, 04:26 PM   #9
scottyb
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Default Re: Ezgo Roypow fail

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Originally Posted by Bama Brad View Post
So, this incident had nothing to do with the Roypow? Just happened to fail when you installed the new Roypow? Am I interpreting that correctly?
Then why was the battery charge post smoking? and the battery shut down
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Old 03-02-2021, 06:04 PM   #10
Bama Brad
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Default Re: Ezgo Roypow fail

I don't mean to be an alarmist, and everything may be OK with your fix. When I got my Roypow, it was about 6 bars if I remember correctly. I do know that Battery will auto shut down shortly after it hits one bar for safety (I had it happen to me out on trail). But I would be concerned if what I interpreted you to say was the charge connection started smoking.
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