Replaced Almost All Critical Components, No Forward Motion

[Scuba]

I have a 2005 EZGO TXT PDS with F/W switch on the dash. The cart will not go forward even on a full charge. It will however go in reverse quite well. Replaced the F/W switch, Solenoid, Speed Sensor Magnet and the Controller which were all original equipment. After the replacement controller was put in, the cart did work for a few days with limited testing. All seemed to be well.
Trailered it to the course, drove it to the first tee and it dies in FWD.
In the case before and now, the controller clicks when the pedal is depressed.
I spent $431 on a controller only to have the same issue which tells me its not that. Not to mention the lesser parts which I now consider "inventory."

Voltmeter tests show battery level at about 37.5v since I did draw down the charge with this limited use and its not recharged yet.
Each battery shows 6.2v and one has a 6.1v reading.
I am really struggling to find the problem here given all I have done.
Can anyone tell me if there is a voltmeter test to determine if the controller is bad?
Or perhaps is there something I am missing to further troubleshoot this issue?
Any help is sincerely appreciated.

Scuba

[as350pilot]

First welcome to BGW, and sorry for your issues.

Here are some links to some diagnostics

EZGO Diags.

http://products.jacobsen.com/img/manuals/28646.pdf

Check the above link starting with page 65.

[scottyb]

I assume you have tested or replaced the F&R rocker switch?
Another culprit on these carts can be the Field wires from controller to motor. They can rub bare at the battery box vertical support and cause havoc with the control. See pic of my cart below.

[Scuba]

Thank you for replying AS350Pilot and Scotty B,

Yes I failed to mention I did replace the F/R rocker switch too.
I will check those field wires for abrasions and the manual is a huge help!
Got some work to do chasing this ghost I guess..........
I sincerley do appreciate your willingness to help me stay off suicide watch

[Scuba]

Question though, some have told me that a 2005 TXT does not have a micro-switch in the pedal box, the manual seems to refer to there being one.
I have not taken off the pedal box cover yet but there certainly is innerduct with wires leading to it.
Any chance this could be a likely culprit?

Thanks,

Scuba

[scottyb]

yes, is the solenoid clicking when you try to go? yes? The problem may not be the ms but the throttle input signal?

Pull the rocker panel, lift the mat, remove the peddle box cover to access the switch.

[Scuba]

Oh the clicking is distinctly there though I never can tell if its the solenoid or the controller making the noise. I shied away from it only because reverse does work and the place I bought it from told me there wasn't even a switch in there.

[scottyb]

My manual says 2005 ezgo PDS has a peddle switch, but if the solenoid clicks it is working.

[Scuba]

I can't catch a break here. All things pointed to a second bad controller, so I replaced it.
All seemed well for about 5 minutes until I tried to drive the cart up onto my trailer.
It just would'nt go up that tiny hill, like it did a millions times before.
Replaced the solenoid, no dice. Error code indicates 2-3 beeps, thermal cutback?
now I am really struggling, is my motor a suspect?
Thanks,

Scuba

[Scuba]

One of the glaring diagnostic measements I have taken is the voltage on the controller terminals F1 and F2 with the pedal fully depressed. The manual reads it should be 2.7v plus or minus .5v. My reading shows 8v with the wheels spinning at full speed?
I'm thinking this could cause a thermal cutback? I am going to press on through the rest though. Any comments or experience is very much appreciated..................thank you