Learning from your mistakes.....

[gornoman]

Long story, but I'll try and not bore you.

Last summer I decided that my cart needed it's wiring spruced up a bit, EZ-Go TXT Series cart, Alltarax controller, other HD items, but bone stock control wiring except where I hacked into it too many times over the years. First mistake: working on a hot system. What could go wrong?

Pffffttttt! One control wire got loose, grounded out (or hit something still hot, who knows?), and the cart is dead. There was a single narrow column of smoke that came from between the F/R assembly and the controller/solenoid area. Inspection showed no obvious melted wires or shorts. Ran through some basic troubleshooting ideas and got the solenoid to fire by using an alligator clip jumper between the solenoid and the main pack +. Cart now ran, but you didn't need the key and the solenoid was always engaged. Decided to put up with for a while this way because it's summer, I'm at the campground to have fun, and tearing apart my cart is not fun like it used to be. A few times we left the jumper in place when we left camp on Sunday until the next Friday when we returned. Solenoid would be warm, but that was it.

Now this spring things got interesting. Decided I would replace the OEM wire control wire harness that goes from the controller-solenoid-f/r switch to the pedal box. The first half of that harness was pretty well hacked by me over the years, so it was a good plan. Installed the new harness and the cart came to life. For about a day, then it would drop out while running occasionally. Finally it stopped altogether. I determined it was the solenoid and Scottyb"s Carts Unlimited sent me out a Super Duty 48v solenoid. Installed it, ran for a while, then nothing. Now what?

New solenoid checks out in a bench test, but fails in the cart. Started tracing wires. Got to the famous 4pin molex connector and found this:



It was pretty dirty, so I hit it up with some compressed air, corrosion cleaner, and contact lube (disregard the wires that are cut off. pix are after the fact). Put it back together, and now the solenoid clicks but the cart wont move. Altrax blinks 4 times signaling EZ-Go ITS throttle setting then goes solid green. Throttle movement would not change the green light to amber. Decided to reinspect the molex connector and noticed this:



At least two of the contacts are burned away or damaged. The second half of that connector was attached to the harness that goes directly to the ITS box in the floorboard. EZ-Go wants $85 for this half, why I don't know, but I said screw it, I can use insulated spade clips just as well, and I did up all four wires nicey-nicey with shrink wrap and everything (second mistake, should have spent the money). Cart is still not driving. WTF!

Started to ohm-out each wire from end to end. The green and red wires control the accelerator microswitch and they were working because the solenoid was firing. The white and black wires carry the ITS signal. White wire ohmed out OK. When I was inspecting the black wire it finally jumped out at me. I looked at the insulated spade connector for the black wire and noticed that when I pressed them together they missed mating themselves inside the insulation. Took them apart, straightened out the male spade, reinserted it and BAM! Everything works again.

Moral of the story: No matter how clever you think you are, there is always room for an unexpected error. Keep checking your work folks!

[Glen Fraser]

dont fell bab about your wiring i hooked up pos and neg to the solenoid took sec to melt every wire in cart.

[Glen Fraser]

to many beers look at that spelling

[cgtech]

Yep, it wouldnt be the only time i crimped the insulation instead of the wire.....nor the last. Always keep your eyes open.....

[DaveTM]

Originally Posted by Glen Fraser

to many beers look at that spelling

It also wouldn't be the first time I "Zigged" when I should have "Zagged" on a project because of beer.

[JohnnieB]

That is why I twist wires together and solder them.

[scottyb]

Glad you found the culprit. This plug connector has been the cause of many long long repair threads.
It's only now that we are learning it may be the Achilles Heel of the Ezgo wire harness.

[gornoman]

Originally Posted by scottyb

Glad you found the culprit. This plug connector has been the cause of many long long repair threads.
It's only now that we are learning it may be the Achilles Heel of the Ezgo wire harness.

Yeah, well there isn't one in MY cart anymore, LOL!