Help with intermittent "No go" issue - 2001 TXT 36v

jpoarch

Hello, golf cart wizards! My wife bought a 2001 TXT 36v series drive cart 2 years ago, and it's been an absolute pain / money pit since. It's lifted with larger tires, and dies intermittently. I've taken it to a local shop twice...they replaced the FNR switch and the batteries(they were old), but we're still plagued.

We can take it out in the neighborhood for a drive, and it will run fine, then it randomly dies. Other times we try to take it out, and it's dead. Full charge on the batteries, and the controller / solenoid clicks when the pedal is pressed, but nothing. The battery wires are in good shape per the shop. The controller is an NPX 4844EZ, and the solenoid is a 36v Trombetta.

It died again on my wife yesterday, and had to tow her back. Started poking around, and found a few things.

1. The pre-charge resistor was broke and the suppression diode looks cut.
2. A ground wire hooked to the solenoid that looks to be hooked to the FNR switch has a blown connector, and is not connected.

I have a few pics, but I just registered yesterday. I guess my question is this...could these be the cause of it randomly dying?

BGW

__________________
This advertising will not be shown in this way to registered members.
Register your free account today and become a member on Buggies Gone Wild Golf Cart Forum

jpoarch

Found out what the black wire is for....reverse beep, which will stay disconnected. It wasn't working earlier, but I jacked the back end up and checked all the wiring between F&R, solenoid, and controller. and now it's running.

Must be a loose or bad wire / connection.

JohnnieB

If the solenoid clicks when the cart is misbehaving, the problem is in the high current circuit.

Put rear of cart on jack stands.
Connect a DVM between the controller's B- and M- terminals.
Push pedal just far enough to make solenoid click and you should read full battery pack voltage. (38.2V when fully charged)
If not, leave the black test lead attached to the B- terminal and use the red test lead to follow the circuit highlighted on the attached schematic to find the missing voltage.

Attached Images

Wiring Diagram - Series- No A2 -Hi-Current traced.JPG (57.9 KB, 0 views)

jpoarch

Thanks JohnnyB! I'll check voltages and report back. Should I be driving it without the resistor and diode? The shop employee said they aren't needed, but I've searched here and found otherwise.

JohnnieB

They aren't "needed" for the cart to run, but the solenoid and pedal switch will last longer if they are installed.

jpoarch

Thanks JohnnieB!

yurtle

Make this guy go away.

Attached Images

Molex.jpeg (254.5 KB, 0 views)

jpoarch

Thanks yurtle....everything I've found here points to this connector being bad. I'll be splicing the wires today.

jpoarch

Removed that 4 pin connector, cleaned up / re-routed the wiring, and added some loom to make it all pretty....cart is running like a champ now...no issues!!

Thanks guys!!

yurtle

Thanks for the followup. Whether suggestions work or not is valuable to current and future readers.