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-   -   Cart arrives "DOA". (http://www.buggiesgonewild.com/electric-ezgo/156222-cart-arrives-doa.html)

btowndan 08-15-2019 01:15 PM

Cart arrives "DOA".
 
I have a 2015 TXT 48 here. When you put it in run nothing happens. The solenoid resistor gets burning hot. My handheld ties to power up but just for a second then nothing. I have tested all that I can think of. I don't work on that many TXT 48's so I'm looking for some guidance:shock::shock: once again.

BobBoyce 08-15-2019 01:52 PM

Re: Cart arrives "DOA".
 
Quote:

Originally Posted by btowndan (Post 1644966)
I have a 2015 TXT 48 here. When you put it in run nothing happens. The solenoid resistor gets burning hot. My handheld ties to power up but just for a second then nothing. I have tested all that I can think of. I don't work on that many TXT 48's so I'm looking for some guidance:shock::shock: once again.

The symptom is the solenoid is not closing, so the resistor is trying to carry all of the current.

btowndan 08-15-2019 02:08 PM

Re: Cart arrives "DOA".
 
That was our first guess so we tried replacing the solenoid and the resistor. No change. Do you have any idea whats keeping it open? I even sent the controller off to FSIP to check out. Got it back and no change. I've tested key switch, Tow/Run switch.

scottyb 08-15-2019 03:00 PM

Re: Cart arrives "DOA".
 
1 Attachment(s)
Attached is a diagram for the TXT48. I have highlighted in red every wire that must have 48v POSITIVE present for the solenoid to close. Note the blue wire must have 48v NEGATIVE when the pedal is depressed and you are trying to go. Hope this helps

btowndan 08-15-2019 03:13 PM

Re: Cart arrives "DOA".
 
Thanks a bunch. Really appreciate ya'll.

nickdalzell1 08-15-2019 04:18 PM

Re: Cart arrives "DOA".
 
A bad controller with failing internal capacitors can cause a cherry red hot resistor as well. When I find out the resistor melted or is glowing red, I always suspect controller.

btowndan 08-15-2019 05:19 PM

Re: Cart arrives "DOA".
 
Quote:

Originally Posted by nickdalzell1 (Post 1645031)
A bad controller with failing internal capacitors can cause a cherry red hot resistor as well. When I find out the resistor melted or is glowing red, I always suspect controller.

We thought as well. That's why I had it checked at FSIP to see. It was fine. As soon as you hit the run switch the voltage drops off a bunch. Chasing down all the controller wires now for continuity and correct voltage.

btowndan 08-15-2019 05:22 PM

Re: Cart arrives "DOA".
 
Quote:

Originally Posted by scottyb (Post 1645000)
Attached is a diagram for the TXT48. I have highlighted in red every wire that must have 48v POSITIVE present for the solenoid to close. Note the blue wire must have 48v NEGATIVE when the pedal is depressed and you are trying to go. Hope this helps

The pedal box wire is green in this cart. I have continuity from the its to the controller. But "zero" volts. micro switch checks fine. Am I missing something here?

btowndan 08-16-2019 10:02 AM

Re: Cart arrives "DOA".
 
OK,
After not being able to find why I'm not getting voltage out of the controller as needed. I was able to jump the negative side of the solenoid and with the key on and run/tow in run the handheld powers up and the cart runs??? Turn the key off and everything shuts down and back to where I started. Now what??:help:

scottyb 08-16-2019 10:15 AM

Re: Cart arrives "DOA".
 
The controller provides solenoid (-) for activation. If not, see diagram,the controller has failed

btowndan 08-16-2019 12:43 PM

Re: Cart arrives "DOA".
 
I have Neg 51v at the blue wire @ the controller pin #12 key off in tow. Key on drops to Neg 49v. Put in run starts dropping voltage all together. The controller came back yesterday from FSIP and is "suppose" to be good?

nickdalzell1 08-17-2019 10:01 AM

Re: Cart arrives "DOA".
 
If I had a dollar for all the times FSIP has sent one back claiming 'there is nothing wrong with it' I'd be rich. Often we get one back they supposedly 'fixed' and it fails again in a few days. Sometimes you get the 'bad' tech others the 'good' tech. It's a 50/50 for us.

The reason you're getting that drop is because there's an open capacitor inside the controller (that's why it pulls enough amps to EOL a resistor). Sometimes we have gotten false 'low battery voltage' errors on the handheld due to this; the controller handheld has AA batteries inside since it won't even power up under this condition--but the batteries allow you to scan it anyways, and under Monitor I see something like 9 volts under battery voltage despite the actual voltage being well into the 50.5 volts range. When you jumped the ground connection to B- you over-ridden the capacitors and allowed the car to run. It will likely have jumped at first since there's no pre-charge circuit anymore. That's what that resistor does--keeps controller capacitors charged to allow less wear and tear on the circuitry and a smoother start when you hit the gas pedal.

btowndan 08-17-2019 11:02 AM

Re: Cart arrives "DOA".
 
Thanks for the info. Makes since. I had another rebuilt controller here so I hooked it up just to see what would happen. I got the same result? Do you think that something is shorting out the controller? Or could I possibly have 2 bad rebuilt controllers?

nickdalzell1 08-17-2019 07:37 PM

Re: Cart arrives "DOA".
 
I'd have replaced that resistor first (also the solenoid if it showed any signs of melted anything) before I'd have replaced the controller. Once they glow cherry red, they're done. Also, you can damage a controller without a proper pre-charge circuit or resistor. FSIP always sends us a little brochure on some tests to run in order to ensure you don't fry the new controller.


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