cart died and smells

[devybob]

My 42 volt western died while driving. It will jerk forward but just creeps and dies again like the batteries are dead,but they are fully charged. I can smell that something burnt but can't find any burnt wires. Where do I start.

42 Volt western, HD solenoid 2 gauge wires, DCX 400A controller.

[Golferdave]

If solenoid is clicking

F&R sw a good place to start

Westerns are a pia to work on

[cgtech]

Smells like rotten eggs? Be on the hunt for the failed battery if so.

[scottyb]

Start with new batteries - trying to run on dead (low) batteries is very bad for the electronics and could cause failure of the controller, motor, F&R, solenoid etc.

[devybob]

batteries are a month old (7) and all checked out about 6.39 volts. full pack voltage is 44.7.Batteries were fully charged last night so the readings are still a little high. solenoid clicks nice and loud. burnt odor is now gone since last night. Tried to see if runs after recharge but cart just shudders and barley moves at all.

[scottyb]

You are describing a battery failure. Attach the voltmeter to one battery at a time and try to go, see if one or more batteries drop more than 1 volt under load of trying to go. If yes replace said batteries, if no, look for bad cable or F&R or motor.

[devybob]

What I did was to put my cart against a building and check the battery voltage while holding the pedal to the floor to put a load on the batteries.All the batteries read 5.9 volts. I assuming this leaves out battery failure. How do I check the F&R switch and motor. Cables all look very good.

[scottyb]

Originally Posted by devybob

What I did was to put my cart against a building and check the battery voltage while holding the pedal to the floor to put a load on the batteries.All the batteries read 5.9 volts. I assuming this leaves out battery failure. How do I check the F&R switch and motor. Cables all look very good.

Putting a cart into a full stall just to check batteries is like cutting your finger off to check your pulse. I would never do it to my cart.
Load is tested using the cart motor under a working load like hard acceleration up hill.
Inspect the F&R studs to see if any stud is a different color than the others or if any of the cables show any sign of ever getting hot. If yes remove the shift linkage & the center pivot nut and slide the pivot shaft and switch cam out of the F&R housing.

Take pics and submit for review

[devybob]

I have a sepex PDS to DCX conversion installed for my alltrax controller so I don't believe I have a F&R switch like you showed me. My F&R switch is on the dash.

[scottyb]

Originally Posted by devybob

I have a sepex PDS to DCX conversion installed for my alltrax controller so I don't believe I have a F&R switch like you showed me. My F&R switch is on the dash.

Always good to ID the drive type to begin with, If the cart goes forward and reverse the sepex F&R test is complete.