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Unread 07-18-2016, 08:15 PM   #1
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Default 2002 ezgo txt lifted ,motor kit problem

Hello I have a 2002 ezgo txt. When I purchased it it was lifted with 22' tires 8 hp motor heavy duty forward reverse switch and 700 amp controller and the heavy duty cables and solenoid. All parts came from buggies unlimited. After burning out 3 forward reverse switches and making some phone calls I was told the controller was to big and was the reason for burning them out. So I just purchased and installed a new alltrax programmable 500 amp and new heavy duty solenoid. After installing these and looking over the wiring diagrams I have nothing. All wiring appears right according to diagrams but when pressing the pedal the solenoid makes no noise. I tested the solenoid out of the cart and you can hear it clicking. This forward reverse switch in it has been hot but the contacts still appear to be make good contact. I was hoping not to have to buy a new fw rev switch as I have also purchased a electric solenoid switch kit to eliminate the fw rev switch from cv drives but did not want to attempt that install until this was taken care of. Any and all input would be greatly appreciated.thanks!!!
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Unread 07-19-2016, 06:58 AM   #2
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Default Re: 2002 ezgo txt lifted ,motor kit problem

well first lets assume that you wired it correctly when replacing the controller. The fact that it doesn't CLICK when you try to go means that there is something wrong in the solenoid activation circuit. The activation circuit is high-lited in the attached drawing. use your DVM to trace everything out and ensure its properly wired and you don't have any OPEN's.

Wiring Diagram Series with Solenoid Activation Traced.JPG


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Unread 07-19-2016, 09:35 AM   #3
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Default Re: 2002 ezgo txt lifted ,motor kit problem

Thank you for the response. I just checked this diagram against what I have and checked the wiring again and everything is hooked up to there spot except the black from solenoid to the fwd rev switch but it never had one on the old one as they said it was just the back up alarm is this true?
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Unread 07-19-2016, 11:00 AM   #4
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Default Re: 2002 ezgo txt lifted ,motor kit problem

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Originally Posted by Tundraxd11 View Post
Thank you for the response. I just checked this diagram against what I have and checked the wiring again and everything is hooked up to there spot except the black from solenoid to the fwd rev switch but it never had one on the old one as they said it was just the back up alarm is this true?
This is very true. SO since its hooked up correctly.....then you need to start checking continuity of each wire in the circuit. Since the solenoid isn't "clicking" with the key on and as you start to push on the accelerator.

WARNING: to be troubleshooting and checking if the cart will GO can be dangerous unless you are sitting in the DRIVERS SEAT...so to be safe, jack up the cart and place the rear wheels it just off the ground on jack stands.
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Unread 07-19-2016, 11:42 AM   #5
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Default Re: 2002 ezgo txt lifted ,motor kit problem

The 700A controller wasn't too big, the F/R switch's high current contacts were too small.
But that is a moot point since you've already bought an Alltrax controller.

Which 500A Alltrax controller did you get, AXE, SPM or SR? (So I can post the correct schematic)

-----------
Since the solenoid isn't clicking, the problem is is in the solenoid activation circuit, which consists of about 4 switches, the solenoid coil and some wire connecting them in series. You say the solenoid clicks when tested outside the cart, so all that's left is three microswitches and a reed switch plus the connecting wires.
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Unread 07-19-2016, 02:36 PM   #6
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Or a bad Alltrax controller like the brand new one I got last week. When I pushed the throttle I got trouble code flashes which Alltrax was able to tell me pointed yo a bad controller. Are u getting any flashes on the controller LED?

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Unread 07-20-2016, 04:54 PM   #7
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Default Re: 2002 ezgo txt lifted ,motor kit problem

I will have to check which model controller it is im not certain its blue if they are different colors. I checked the reed switch and the switches on fw rev switch and they check out ok but my micro switch in the pedal box what is the proper way to test that? I checked it for continuity and it does not have it. Does anyone know of anyone in the New York area that works on carts like these? Also my controller status light does not light up at all or flash, does that sound right ,or should it at least light up without solenoid working? Thanks so much for all the help so far!
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Unread 07-20-2016, 06:53 PM   #8
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Default Re: 2002 ezgo txt lifted ,motor kit problem

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Originally Posted by Tundraxd11 View Post
I will have to check which model controller it is im not certain its blue if they are different colors. I checked the reed switch and the switches on fw rev switch and they check out ok but my micro switch in the pedal box what is the proper way to test that? I checked it for continuity and it does not have it. Does anyone know of anyone in the New York area that works on carts like these? Also my controller status light does not light up at all or flash, does that sound right ,or should it at least light up without solenoid working? Thanks so much for all the help so far!
The status LED illuminates at the same time the solenoid clicks since the voltage from the pedal microswitch that energizes the solenoid also powers up the controller.
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Unread 07-20-2016, 06:54 PM   #9
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My solenoid wasn't clicking but when I applied the throttle I would get my LED trouble codes.

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Unread 07-20-2016, 07:28 PM   #10
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Default Re: 2002 ezgo txt lifted ,motor kit problem

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My solenoid wasn't clicking but when I applied the throttle I would get my LED trouble codes.

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So?

FWIW: The original poster has not identified which of the Alltrax series drive controllers he has yet, but his symptoms are no solenoid click and no LED, so he has a bad pedal microswitch or at least something is amiss with the switches and wires that feed the solenoid's small terminal with the red wires on it.

You haven't identified which controller you have either, but it sorta-kinda sounds like it is also a series drive and your symptom are no solenoid click with the LED illuminating on the controller, which are an entirely different set of symptoms.

Since the LED on the controller illuminated, but no click from the solenoid, I suspect you had the black wire on the solenoid connected to the relay terminal on the solenoid. That points to either a bad solenoid coil or a bad controller, and the need for additional troubleshooting.

At this point in time, I do not suspect the original poster has a bad controller since the conditions needed for the controller to power up are not being met, or at least their being met has yet to be proven.
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