EZGO TXT killing me

[Deshawnj]

Hi All, I have a 2005 EZGO TXT PDS cart that had a bad controller. Replaced with another stock curtis controller and a new solenoid along with a new run tow switch. Rode for about 10 minutes and it died in the middle of the road.

Got it home and jack stand tested the motor it still works fine.

I can press the pedal and hear the solenoid click, but that is all.

I checked for loose connections, I have no corrosion on posts or cuts in the rubber around any wires to cause a short that I can see.

I don't know where to start, I once read on here that if the solenoid clicks that means it is a large cable circuit issue.. motor controller batteries. Is that correct? Batteries charge to about 38 volts full charge but they are 4 years old. Any help is greatly appreciated as always.

[scottyb]

Personally I wouldn't mess around with another stock replacement. If you need a control get an Alltrax. Check the F&R switch. They do corrode with age depending upon your environment. Also solenoids can click and not pass current. Check for power going through the 2 big posts when it clicks.

[Deshawnj]

Thanks ScottyB. I have one to try, So the actual push button FNR switch on the dash if corrosion set in could become faulty where during a ride the cart wouldn't know that it needed to move in a direction.

Would this allow the solenoid to still "click" when the pedal is pressed?

[scottyb]

Possibly yes.

[coosa]

A bad ITS caused mine to die suddenly like that, but it would start back up later. I have no idea that this is your problem, but keep it in mind.

I agree with Scotty on the controller. I think that most anyone who is trying to do their own mechanic work on a PDS cart would be better off to upgrade the controller. Who doesn't want more power and speed?

Whatever your problem, you will figure it out and soon be running again. Reading this forum makes me thankful for my PDS carts. At least you have some real brakes on it.

[Deshawnj]

I have a few EZGO pds carts that allow me to swap parts.

Controller worked.
Solenoid worked.
ITS worked.
Key switch worked.
FNR switch worked.

I disconnected all the cables to the motor and put the rear on jacks.

Jumped A1 to F1 and A2 to F2 put jumper cables to the A cables and an 18 volt battery nothing. Battery would spark but no movement, even tried to push the tires a little nothing.

Do the same on the other PDS cart I have and it spins the motor right away.

Before I pull out this motor, is there a way to test the posts on it with a meter to verify it is bad?

Thanks for all the help guys.

[scottyb]

With an ohm meter and the cables disconnected.; there should be continuity between the 2 A and between the 2 F terminals but no continuity between any A and any F terminal.

[Deshawnj]

Awesome thanks Scottyb.

If any of those fail the whole motor is failed correct.

[scottyb]

Originally Posted by Deshawnj

Awesome thanks Scottyb.

If any of those fail the whole motor is failed correct.

Correct. It is not uncommon for a failed motor to take out the controller. Modern controllers like Alltrax have built in reverse polarity protection unlike the OEMs.

[Deshawnj]

Thanks ScottyB. It was the motor.

When I was able to get the motor off and the end cap off.

Two of the cables connecting to the brushes were melted off and not connected to the brushes anymore.

The wires at the terminals were still connected but at the actual brushes they melted off.

A new set of brushes should do the trick.