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Electric EZGO Electric EZ GO Marathon, Medalist, TXT and RXV.



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Old 04-25-2013, 07:49 PM   #1
Restoredude
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Default 36v txt non pds won't run

So I am new to this site, but not to restoring things but I will admit this is my first go cart. I have a 2001 TXT 36 non pds motor, with the f/r switch under my legs. I have new batteries, new 400a alltrex npx controller, stock f/r switch, stock solenoid and a new plum quick bandit motor. i have a 4" lift and 20" tires.

This setup has worked fine for several months using the oem ezgo controller until several weeks ago when i came home to find my teenage son pushing the golf cart home. he had been doing high speed runs down a steep hill! geez kids! I saw the stock controller had gotten pretty heated up and the cover was partially melted, thus I thought oh well its the controller and purchased the alltrax model noted above. put it in and still no go. i have full battery voltage 38.2v, I hear the solenoid clicking, the controller indicator light gives me a solid green light, then amber light with the pedal all the way down so I assume the pedal box is working correctly. I have full voltage between b- and m- and with the pedal all the way down i have 20v which i think is a little high. I checked the f/r micro switches and they seem to pass the voltage when engaged in either f or r but maybe i missed something? could he have possibly burned the motor up? I am going to order a new HD solenoid for sure and I know everyone would suggest a HD f/r switch as well. Any suggestions on what else to trouble shoot?
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Old 04-25-2013, 09:51 PM   #2
Andy4639
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Wink Re: 36v txt non pds won't run

Put a jumper wire on the 2 large terminals of the solenoid and see if it will run then. Jack it up though first. If so it's the solenoid is bad. Just because it clicks doesn't mean it's good!
U may want to change the F/R handle out for a F/R contactor much more reliable.
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Old 04-26-2013, 08:35 AM   #3
Restoredude
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Default Re: 36v txt non pds won't run

If I get voltage on both sides of the solenoid even w cart off I assume its welded closed correct? Cuz that's what has happened. So if the controller is getting 36v all the time and outputting voltage as indicated by the diagnostic inboard light why won't wheels turn. I have a c200a solenoid on the way and will try that. I needed to upgrade anyways
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Old 04-26-2013, 08:40 AM   #4
scottyb
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Default Re: 36v txt non pds won't run

2 things come to mind.
1. if you test the solenoid for voltage with the resistor in place you will always have pack voltage on both big terminals.
2. if you high speed run test the motor it may over rev and burn up.
When that happens they usually take the controller out too.
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Old 04-26-2013, 09:30 AM   #5
JohnnieB
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Default Re: 36v txt non pds won't run

Quote:
Originally Posted by Restoredude View Post
i have full battery voltage 38.2v, I hear the solenoid clicking, the controller indicator light gives me a solid green light, then amber light with the pedal all the way down so I assume the pedal box is working correctly. I have full voltage between b- and m- and with the pedal all the way down i have 20v which i think is a little high.
First:
When the controller powers-up, the Green LED should blink 4 times, indicating the controller is programmed for an ITS type throttle.

Cut&paste from Alltrax website NPX page:
The LED Blink Codes occur at power up, the number of green blinks indicates the throttle configuration:

1 Green LED flash = 0-5 kohm resistive
4 Green LED flashes = EZ-GO inductive (ITS)
7 Green LED flashes = ClubCar 5k-0 ohms, 3-wire throttle


Second:
The 20V with pedal down is high, but the solenoid contacts may be bad and you might be reading some the voltage through the pre-charge resistor
Disconnect the pre-charge resistor from the large terminals on the solenoid and measure between M- and B- again.

Should be full battery pack voltage when solenoid first clicks and then decrease all the way down to Zero volts (or at lest less than a volt) when pedal is on floor.
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Old 04-26-2013, 01:34 PM   #6
Restoredude
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Default Re: 36v txt non pds won't run

scotty...yes i have the resistor in place so that maybe why i am getting 36v on both sides of the solenoid, regardless i am replacing it with a higher 200a continous solenoid just for future and safety sake. And yes I am afraid the motor may have burned up I am trying to eliminate all other areas before I pull it and send it back for rebuild as its only 2 months old but the over revs worries me.

johnnie...yes i get the 4 flashing green lights first, then green, then amber. I get no blinking red lights for errors so as far as the controller is concerned it thinks its functioning fine right? i also checked all my connections to the f/r and they are tight, not burned up and the contacts don't look dark. I have 4ga cables and they are not burned up and the connections to the motor are not loose.
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Old 04-28-2013, 08:13 AM   #7
yurtle
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Default Re: 36v txt non pds won't run

I have a used series motor, HD 36 volt solenoid, and stock controller that I out grew. Motor has new bearing and good brushes. PM me if interested.
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Old 05-17-2013, 07:12 PM   #8
Restoredude
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Default Re: 36v txt non pds won't run

I am happy to report that I upgraded the solenoid to a 200A model, upgraded the diode and resistor to match then changed the reed switch and varoooom it came to life today! the motor wasn't burned out after all so that is a big relief.
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