What burnt up???

EZGO_N_TAHOE · 12-20-2015, 03:01 PM

OK guys, I need your help.... I have a 96 EZGO TXT electric cart 36V The other day the kids took the cart out and it started smoking and then died. Had to push the cart home. I looked under the seat at the batteries and there was some corrosion build up on 4 of the six batteries. I know for a fact that this build up had to have happened in the last month, cause I always check them. It has been pretty cold here in Tahoe. Anyway, I cleaned up all the corrosion, charged the cart and I am at 38.2 volts. I turn the ignition on, put it in forward and press the pedal and the cart wont go. I hear it "click" when I press the pedal at the controller under the seat. Cart wont move in reverse either. Not sure what to check of what maybe burnt up. My cart has the upgraded power controller that I got from ScottyB at carts unlimited....Any thoughts or input would be appreciated....Thanks guys!

JohnnieB · 12-20-2015, 03:52 PM

Which drive system, Series or SepEx? (If there is a Run/Tow switch, it is a SepEx drive. - Make/model of controller would also tell us)

If the solenoid clicks when the pedal is pushed, the problem is in the high current circuit.

If known, what general vicinity did the smoke come from?

12-20-2015, 03:58 PM

johnny b is here ... im quiet

EZGO_N_TAHOE · 12-20-2015, 04:23 PM

It does have the maintenance/tow switch so it is the Sepex. The speed controller is this one:

Pkg. #505
400amp Alltrax (DCX400) 36-48v programmable controller and
200a continuous/800a peak Solenoid in 36 or 48 volt

Not sure where the smoke was coming from (besides under the seat), and I don't see anything "burnt up"

Volt_Ampere · 12-20-2015, 04:35 PM

Use your nose and find the smoked component. My money is on the controller if none of your battery posts are melted.

JohnnieB · 12-20-2015, 04:54 PM

Okay, you have a 1996 TXT DCS with a DCX400 controller in it. (Schematic attached)

Does the LED on the controller go to steady green after it flashes green 4 times, or does it flash a RED error code?

If it goes to steady green, connect a voltmeter between the controller's B- and M- terminals.
Push pedal just far enough for solenoid to click and you should read full pack voltage (38.2V?)

If not, there is an open or bad connection in the high current cables or motor.

If you do get pack voltage, push pedal slowly to the floor (rear wheels off ground for safety) and the voltage between B- and M- should decrease to zero.

If not check the ITS (Throttle) input to controller.
Measure between pins 1 & 2 in 10 pin connector on top of controller.
Pedal up should be 10V and pedal on floor should be 6V.

----------
Also check F1 & F2 cable for worn insulation where they are routed around battery frame. (Picture attached)

JohnnieB · 12-20-2015, 05:12 PM

Quote:

Originally Posted by Volt_Ampere

Use your nose and find the smoked component. My money is on the controller if none of your battery posts are melted.

I won't bet against that possibility.

But the darnedest things can happen when kids drive carts.

FWIW: Attached is an Alltrax Technical note on how to "Diode" check a DCX controller and another one on troubleshooting a DCX.

EZGO_N_TAHOE · 12-20-2015, 05:26 PM

JohnnieB, it flashes red after the 4 green blinks......is there a fix for that? thanks, Ron

EZGO_N_TAHOE · 12-20-2015, 05:35 PM

Great!!! it blinks red 5 times after depressing the gas pedal. it doesn't say what to do for 5 red blinks in the troubleshooter.

JohnnieB · 12-20-2015, 05:53 PM

Quote:

Originally Posted by EZGO_N_TAHOE

Great!!! it blinks red 5 times after depressing the gas pedal. it doesn't say what to do for 5 red blinks in the troubleshooter.

5 RED blinks is an Open Field circuit. (See attached)

Could be open F1 or F2 cable, bad motor or bad controller.

Check the Field cables and motor with an Ohmmeter and do the diode test on the controller.

12-20-2015, 03:01 PM	#1
EZGO_N_TAHOE Not Yet Wild Join Date: Feb 2015 Posts: 32	What burnt up??? OK guys, I need your help.... I have a 96 EZGO TXT electric cart 36V The other day the kids took the cart out and it started smoking and then died. Had to push the cart home. I looked under the seat at the batteries and there was some corrosion build up on 4 of the six batteries. I know for a fact that this build up had to have happened in the last month, cause I always check them. It has been pretty cold here in Tahoe. Anyway, I cleaned up all the corrosion, charged the cart and I am at 38.2 volts. I turn the ignition on, put it in forward and press the pedal and the cart wont go. I hear it "click" when I press the pedal at the controller under the seat. Cart wont move in reverse either. Not sure what to check of what maybe burnt up. My cart has the upgraded power controller that I got from ScottyB at carts unlimited....Any thoughts or input would be appreciated....Thanks guys!
EZGO_N_TAHOE Not Yet Wild Join Date: Feb 2015 Posts: 32

12-20-2015, 03:52 PM	#2
JohnnieB Techno-Nerd Join Date: Jun 2011 Location: West Virginia Posts: 19,654	Re: What burnt up??? Which drive system, Series or SepEx? (If there is a Run/Tow switch, it is a SepEx drive. - Make/model of controller would also tell us) If the solenoid clicks when the pedal is pushed, the problem is in the high current circuit. If known, what general vicinity did the smoke come from?

12-20-2015, 03:58 PM	#3
crash test dummy Guest Posts: n/a	Re: What burnt up??? johnny b is here ... im quiet
crash test dummy Guest Posts: n/a

12-20-2015, 04:23 PM	#4
EZGO_N_TAHOE Not Yet Wild Join Date: Feb 2015 Posts: 32	Re: What burnt up??? It does have the maintenance/tow switch so it is the Sepex. The speed controller is this one: Pkg. #505 400amp Alltrax (DCX400) 36-48v programmable controller and 200a continuous/800a peak Solenoid in 36 or 48 volt Not sure where the smoke was coming from (besides under the seat), and I don't see anything "burnt up"
EZGO_N_TAHOE Not Yet Wild Join Date: Feb 2015 Posts: 32

12-20-2015, 05:26 PM	#8
EZGO_N_TAHOE Not Yet Wild Join Date: Feb 2015 Posts: 32	Re: What burnt up??? JohnnieB, it flashes red after the 4 green blinks......is there a fix for that? thanks, Ron
EZGO_N_TAHOE Not Yet Wild Join Date: Feb 2015 Posts: 32

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12-20-2015, 04:35 PM	#5
Volt_Ampere Gone Wild Join Date: May 2012 Location: Rio Verde, Az Posts: 7,170	Re: What burnt up??? Use your nose and find the smoked component. My money is on the controller if none of your battery posts are melted.

12-20-2015, 05:35 PM	#9
EZGO_N_TAHOE Not Yet Wild Join Date: Feb 2015 Posts: 32	Re: What burnt up??? Great!!! it blinks red 5 times after depressing the gas pedal. it doesn't say what to do for 5 red blinks in the troubleshooter.
EZGO_N_TAHOE Not Yet Wild Join Date: Feb 2015 Posts: 32

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