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Electric EZGO Electric EZ GO Marathon, Medalist, TXT and RXV.



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Old 08-05-2017, 10:23 AM   #11
Shootnjohn
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Default Re: 2002 TXT Tries to go, but...

I also swapped out the harness with the 9=pin connector on the controller with the older one I had taken off, no change.
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Old 08-05-2017, 03:27 PM   #12
Raystar57
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Default Re: 2002 TXT Tries to go, but...

Bummer on the Tahoe and on the F/R switch.

Are you sure the key switch and its terminal connections are in good shape?
The wiring from the key switch goes to the F/R switch and may be intermittent.

I agree that the solenoid and controller should be good as it does run as you stated, just intermittent.

Quote:
The on/off switch was replaced within the last year by a dealer along with new headlights and taillights.
The forward/reverse switch is on the dash and an on/off toggle switch in under the seat on the passenger side.
EndQuote:

Are you saying that the key switch was replaced or just the tow/run under the seat?

Here are some tips from cartsunlimited (scottyb) a site sponsor that may help.

http://www.cartsunlimited.net/troubleshooting-tips.html
http://www.cartsunlimited.net/ezgo-troubleshooting.html
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Old 08-05-2017, 06:59 PM   #13
yurtle
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Default Re: 2002 TXT Tries to go, but...

A solenoid can become intermittent. Two of mine did.
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Old 08-06-2017, 11:29 AM   #14
Shootnjohn
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Smile Re: 2002 TXT Tries to go, but...

Today I was doing some of the diagnostic testing someone provided, Thank You. As I did, the motor started running normally. I reconnected the resistor in the solenoid and it is still working normally in Forward and Reverse.

One anomaly is that when reading voltage from Batt Main - to the Positive side of the solenoid, batt voltage is present. But, when checking from Batt Main - to the other side of the solenoid batt voltage is also present. When the solenoid is then engaged and disengaged the voltage never drops to 0. I guess this is an internal failure of the solenoid and I will replace it tomorrow. Should I be replacing the resistor also? I didn't think to measure it while I had it disconnected.

Thanks again.
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Old 08-06-2017, 12:32 PM   #15
Raystar57
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Default Re: 2002 TXT Tries to go, but...

This sounds like a welded closed solenoid condition.
As yurtle stated the solenoid can become intermittent.
I had thought it was good but there is obviously an issue here.
If the resistor is not burnt looking it is probably ok but you could just replace it as they are cheap.
I think it's 250ohm and 5-10watt.
If it is open or low resistance this can cause issues with the controller and increase solenoid contact arcing.
I think the controller does a quick check on it to insure it's not in a welded or stuck condition.
If it doesn't like what it sees it will prevent the cart from moving or go into limp mode from what I understand.

Also is there a diode across the small terminals of the solenoid?
It should have one to protect the coil of the solenoid.
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Old 08-07-2017, 10:55 AM   #16
Shootnjohn
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Default Re: 2002 TXT Tries to go, but...

OK, today I replaced the solenoid and the resistor. There was no diode on the solenoid so I did not put the new diode on, since I was not sure of the proper connection.

The cart runs now, but do I need to put the diode on? When I read voltage from Main Batt - to the small terminal with the blue wire it reads battery voltage. When I read to the other terminal which has an orange or dark yellow wire, I get the same voltage reading. This is before the solenoid clicks on.

I have it on charge now to check final individual battery voltages at full charge.

Any comments about the diode connection? I don't want to connect it backwards and burn it up.

As always, Thanks
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Old 08-07-2017, 10:33 PM   #17
cgtech
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Default Re: 2002 TXT Tries to go, but...

Quote:
Originally Posted by Raystar57 View Post

Also is there a diode across the small terminals of the solenoid?
It should have one to protect the coil of the solenoid.
Just to clarify, the diode is to protect the microswitch at the pedal (and probably the controller logic board). The diode has a silver band on one end, it points toward the positive wire on the solenoid small terminals.
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Old 08-08-2017, 11:55 AM   #18
Shootnjohn
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Default Re: 2002 TXT Tries to go, but...

Understand the purpose of the diode, but was not sure which was the positive terminal.

Continuing the saga...

Today I put it up on jackstands. Now when I turn it on and there is no light on the controller and the solenoid will not click. Also, the ITS voltage at pins 1 and 2 is from 7.6V to about 4.3V.

I am about ready to give up on this.
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Old 08-08-2017, 01:20 PM   #19
Raystar57
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Default Re: 2002 TXT Tries to go, but...

Don't give up!

First we need to know what the battery pack voltage is now since you have charged it and it has sat awhile.

It seems like a low voltage supply condition to the controller which could be from a low pack or bad cable.
You may have a bad battery in the pack.
If you get 38.2 or near 38.0 then the pack is charged well.
Just want to clear that up.

Then with Tow/Run in the run position and key off check voltage from:
B- on controller (neg) to pin 9 (logic B+) on the 10 pin DCX controller.
B- on controller (neg) to pin 10 (B+ power) on the 10 pin DCX controller.
These will be about .7v lower than pack voltage due to diode drop.
This will confirm the controller is powered correctly.

We can go from there is all of this is good.

I have included the schematic and the SOC diagram that Sir Nuke posted.
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Old 08-08-2017, 03:11 PM   #20
kgsc
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Default Re: 2002 TXT Tries to go, but...

Take a deep breath, give it a good swift kick and regroup. You more than likely have a bad wire or switch somewhere that can be found.. The instructions above are a good start
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