TXT ITS micro replacement...

gornoman · 09-22-2008, 07:12 PM

The cart started acting different. I noticed that whenever I turned the key ON, I would hear the solenoid click. Never did that before. Also, leaving the cart sit would heat up the solenoid if the key was left on and the cart was in gear (something that might happen if you were to stop at another campsite and sip a beverage while sitting in the cart yapping on the edge of the roadway). I suspected the ITS microswitch had failed.

You can access the ITS micro by removing the driver's side chrome running board. The longer plastic running board can stay attached:

ezgo throttle

Work the floor mat out from under the running board lip and peel it back to reveal the ITS access panel:

ezgo electric throttle

Remove the access panel and there are 4 screws holding the ITS cover on. Remove the 4 screws to reveal the damage:

ITS throttle

If you look closely you will see the actuator arm has fallen off the micro and landed on the insulated spade connector of the green wire. I removed the switch and replaced it with a temporary jumper:

ezgo throttle micro switch

Simple job, and I will replace the jumper with a new switch next week.

mbz4man · 10-07-2008, 05:20 PM

You guys have been a tremendus help. Thanks to all!

Ken

gornoman · 10-07-2008, 06:08 PM

Are you up and running, Ken?

mbz4man · 10-07-2008, 10:24 PM

Well not exactly, I broke out all the circuits and checked all switches and have determined they are all correctly wired and switching like they should. Early on when I was assembling and testing the circuits, I inadvertantly jumped power to the negative terminal instead of the positive side of the solenoid. (trigger side of course). After some brief McGiver welding I think thats when the failure occured. I checked the diode between the terminals and it is still ok. I have a feeling I smoked the controller! Oops...
When the solenoid is energized the cart should move if in gear and throttle applied right?? Also as a note. I have gone over and cleaned all connections and other electrical basics. Also there is 2.5 ohms resistance in the pedal microswitch when closed. Is this too high, I usually like to see no more than 1 ohm in a basic switch.

Any thoughts on my diagnosis.
Ken

Andy4639 · 10-08-2008, 01:03 AM

The selonoid clicking doesn't mean it's workin' I would check the selonoid with a jumper and as you described and see if it runs.
Jumper the two big terminals with a peice of wire and see if the cart runs. If t does buy a new selonoid.

gornoman · 10-08-2008, 06:57 AM

Quote:

Originally Posted by mbz4man

Early on when I was assembling and testing the circuits, I inadvertantly jumped power to the negative terminal instead of the positive side of the solenoid. (trigger side of course). After some brief McGiver welding I think thats when the failure occured. I checked the diode between the terminals and it is still ok. I have a feeling I smoked the controller! Oops...
Ken

Ken, go back and verify that the reed switch is still working properly. It is not uncommon for them to fail during a "welding" incident. This failure will stop the cart dead in it's tracks.

mbz4man · 10-08-2008, 09:19 AM

When you say reed switch are you refering to the microswitch in the pedal box?

gornoman · 10-08-2008, 09:24 AM

No, the reed switch is a safety interlock inside the cart charge receptacle. It's function is to shut the cart down when the charger is plugged into the cart.

mbz4man · 10-08-2008, 05:25 PM

Ok, Now that makes sense. I will check it out now.
Thanks again!

Ken

mbz4man · 10-10-2008, 09:55 PM

Question regarding the reed switch. Is this reed switch closed or open when the charger is NOT connected? Looks to me like the switch should be closed when charger is disconnected.

Ken

09-22-2008, 07:12 PM	#1
gornoman Stay thirsty my friends! Join Date: Jan 2007 Location: Suburban Chicago Posts: 24,291	TXT ITS micro replacement... The cart started acting different. I noticed that whenever I turned the key ON, I would hear the solenoid click. Never did that before. Also, leaving the cart sit would heat up the solenoid if the key was left on and the cart was in gear (something that might happen if you were to stop at another campsite and sip a beverage while sitting in the cart yapping on the edge of the roadway). I suspected the ITS microswitch had failed. You can access the ITS micro by removing the driver's side chrome running board. The longer plastic running board can stay attached: Work the floor mat out from under the running board lip and peel it back to reveal the ITS access panel: Remove the access panel and there are 4 screws holding the ITS cover on. Remove the 4 screws to reveal the damage: If you look closely you will see the actuator arm has fallen off the micro and landed on the insulated spade connector of the green wire. I removed the switch and replaced it with a temporary jumper: Simple job, and I will replace the jumper with a new switch next week.

10-07-2008, 05:20 PM	#2
mbz4man Not Yet Wild Join Date: Oct 2008 Location: Sunny San Jose, Ca. Posts: 12	Re: TXT ITS micro replacement... You guys have been a tremendus help. Thanks to all! Ken

10-07-2008, 06:08 PM	#3
gornoman Stay thirsty my friends! Join Date: Jan 2007 Location: Suburban Chicago Posts: 24,291	Re: TXT ITS micro replacement... Are you up and running, Ken?

10-07-2008, 10:24 PM	#4
mbz4man Not Yet Wild Join Date: Oct 2008 Location: Sunny San Jose, Ca. Posts: 12	Re: TXT ITS micro replacement... Well not exactly, I broke out all the circuits and checked all switches and have determined they are all correctly wired and switching like they should. Early on when I was assembling and testing the circuits, I inadvertantly jumped power to the negative terminal instead of the positive side of the solenoid. (trigger side of course). After some brief McGiver welding I think thats when the failure occured. I checked the diode between the terminals and it is still ok. I have a feeling I smoked the controller! Oops... When the solenoid is energized the cart should move if in gear and throttle applied right?? Also as a note. I have gone over and cleaned all connections and other electrical basics. Also there is 2.5 ohms resistance in the pedal microswitch when closed. Is this too high, I usually like to see no more than 1 ohm in a basic switch. Any thoughts on my diagnosis. Ken

10-08-2008, 01:03 AM	#5
Andy4639 48/400/Alltrax HS motor Join Date: Jan 2007 Location: Liberty SC, Garden City SC Posts: 6,190	Re: TXT ITS micro replacement... The selonoid clicking doesn't mean it's workin' I would check the selonoid with a jumper and as you described and see if it runs. Jumper the two big terminals with a peice of wire and see if the cart runs. If t does buy a new selonoid.

Today
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10-08-2008, 09:19 AM	#7
mbz4man Not Yet Wild Join Date: Oct 2008 Location: Sunny San Jose, Ca. Posts: 12	Re: TXT ITS micro replacement... When you say reed switch are you refering to the microswitch in the pedal box?

10-08-2008, 09:24 AM	#8
gornoman Stay thirsty my friends! Join Date: Jan 2007 Location: Suburban Chicago Posts: 24,291	Re: TXT ITS micro replacement... No, the reed switch is a safety interlock inside the cart charge receptacle. It's function is to shut the cart down when the charger is plugged into the cart.

10-08-2008, 05:25 PM	#9
mbz4man Not Yet Wild Join Date: Oct 2008 Location: Sunny San Jose, Ca. Posts: 12	Re: TXT ITS micro replacement... Ok, Now that makes sense. I will check it out now. Thanks again! Ken

10-10-2008, 09:55 PM	#10
mbz4man Not Yet Wild Join Date: Oct 2008 Location: Sunny San Jose, Ca. Posts: 12	Re: TXT ITS micro replacement... Question regarding the reed switch. Is this reed switch closed or open when the charger is NOT connected? Looks to me like the switch should be closed when charger is disconnected. Ken

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