Intermittent fault Series TXT

[dvmartin]

Problems with a 2000 TXT with series and a curtis controller. It seems to work fine sometime and then sometimes will not move at all. The solenoid always clicks but sometimes no movement. I thought it might be the molex connector so removed and made straight through soldered connections. That did not solve the problem. Could it be a faulty solenoid that is not making contact at times even though it clicks?

[mgray70]

Check the lugs on the back of the forward and reverse switch. Make sure they are snug, and check for any signs of heat discoloration.

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[dvmartin]

Yes had already checked the F&R and it is all in good shape.

[scottyb]

Solenoids can click without making contact. Easy enough for a cart tech to check

[dvmartin]

I've replaced the solenoid and the cart seems to run fine. Of course it seemed to run fine (Intermittently) too with the old solenoid. I plan to dissect the quesitionable solenoid and will report.

[dvmartin]

I dissected the solenoid that I believe was giving me the intermittent running problem.

The pre charge resistor measured 250 ohms and the diode checked out OK.

In the attached pics you can see that the contact plate had some pitting as did the contact lugs. The contact lugs both had a rough spot at one edge.
Although not as bad as I expected, I could see that as the plate rotates upon activation that if it hits a spot that has a bit more pitting that it would not let the power go through.

The cart with its new solenoid (a higher grade than that which came out) is running fine so far.

[dvmartin]

Well it wasn't the solenoid. Worked fine on Saturday, would not work on Sunday. Solenoid still clicks and power going through to controller. Replaced ITS on the off chance that that might be it. No change with a new ITS. So either the controller (and I have not seen intermittent no go from a controller, it either works or doesn't.)

My next step is to check the motor itself. Perhaps brushes / commutator are going bad.

[scottyb]

I did a write up years ago on the design fault of the side post solenoid. The terminals turn inside when tightening big nuts. This results in a reduced contact surface area. which leads to failure.

Basically get yourself a top terminal solenoid if a failed solenoid is the problem.

[mgray70]

Originally Posted by dvmartin

Well it wasn't the solenoid. Worked fine on Saturday, would not work on Sunday. Solenoid still clicks and power going through to controller. Replaced ITS on the off chance that that might be it. No change with a new ITS. So either the controller (and I have not seen intermittent no go from a controller, it either works or doesn't.)



My next step is to check the motor itself. Perhaps brushes / commutator are going bad.

I have seen a few intermittent controllers before! They are difficult to verify!

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[dvmartin]

Well, it was the controller. Old Curtis 1206. After checking and replacing the solenoid and ITS, the only thing remaining was the controller. Installed an AXE 4844 and everything runs fine. I am going to take apart the old Curtis and see if there is any visable damage.