EZGO txt series DOA throttle issue

[JohnnieB]

If the new 150A rated solenoid is getting "very hot", it is either defective, or the wrong voltage coil, or an abnormally high number of amps are being drawn.

Verify the coil is designed to operate at 36V.

Check cart for excessive drag. Push cart by hand on level pavement. It weighs half a ton, so some effort is needed to get it moving, but once moving it shouldn't take much effort to keep it moving. (Dragging brakes, bad bearings and the like will cause excessive drag)

Driving very slowly (walking speed or less) will draw a lot of amps.

[Twizted]

Rolls smooth, had to push it home lol. Acceleration is at full speed. Solenoid is marked with 36v but maybe it could be defective.

[JohnnieB]

If it isn't the solenoid, it's likely to be the controller.

[Twizted]

Originally Posted by JohnnieB

If it isn't the solenoid, it's likely to be the controller.

Is it typical for the controller to get hot in this situation? It's cool as a cucumber after.

[Twizted]

Changed back to stock solenoid but with new cable. Everything operates correctly now but solenoid get burning hot still. Looks like I have a strange one on my hands.

[JohnnieB]

Originally Posted by Twizted

Is it typical for the controller to get hot in this situation? It's cool as a cucumber after.

If there is a lot of amps being passed, the controller gets pretty warm.

The MOSFETs use the M- bus bar for their heatsink, so it'll heat up first and most. Followed by B+ and then B-. It takes a while longer for the case to warm up.

Originally Posted by Twizted

Changed back to stock solenoid but with new cable. Everything operates correctly now but solenoid get burning hot still. Looks like I have a strange one on my hands.

If the controller and cables are staying cool and only the solenoid (two different ones) is getting hot, I'd try a third solenoid and if it gets hot also, I'd install an Alltrax SR48400 controller.

With the SR controller, you can record data logs that show the amps and volts at various places and temperatures of the M- and B+ buss bars.

It is a strange one.

[Twizted]

Check this out, someone tried to put there own crimp on and just moisture in the air has been wicking up in this cable. Picture of the other end that must be tinned from the factory just on the ends or something?

[Mooncarter]

I think you may have found the problem.

Just curious, is the solenoid clicking like it is supposed to as JB asked?

[Twizted]

Originally Posted by Mooncarter

I think you may have found the problem.

Just curious, is the solenoid clicking like it is supposed to as JB asked?

Yes, When it works at least. I replaced (most cables) with 2awg welding cable that is 34awg strands, Over 1600 strands with tinned cable lugs and finished with glue bonded marine heat shrink. Still shuts down sometimes, solenoid gets really overheated and after a cooling period will make contact again. Maybe that cable could have induced something that put extra wear on it. I plan to try a sw180 solenoid soon.