Cart no go go no mo

[JohnnieB]

Looks like you have a series drive with with a Curtis 1204 (or 1205) controller rather than the Curtis 1206 controller usually found in a 2003 TXT.

Lift at least one (preferably both) rear tire off ground so cart won't move.
Connect your DVM between the controller's B- and M- terminals.
Press pedal just far enough to make solenoid click and you should read full battery pack voltage.

If you don't, trace the high amp cables until you find the missing voltage. F/R switch is the most likel suspect.

If you do, press pedal to floor and voltage ought to decrease to 0V. If it doesn't, either the throttle input to the controller, or the controller itself is bad.

If controller is bad, replace it with an Alltrax SR48400 (or larger) user programmable controller with compatible solenoid.

[Chris379]

So far I get a reading of 13.31v across m- and b-. Testing ongoing....

[Chris379]

So there are 4 high voltage wires off the switch. 3 read pack voltage both in f and r BEFORE pressing the pedal. After pressing the pedal it drops down about 11v to 25v. The bottom one closest to the ground (grass/street) reads 0 both before and after pressing pedal. This is the same lead that goes to M-.

[JohnnieB]

Originally Posted by Chris379

So far I get a reading of 13.31v across m- and b-. Testing ongoing....

If this is when the pedal is pushed just far enough to make solenoid click, then there is a bad contact, connection or cable in the high amp circuit.

Originally Posted by Chris379

So there are 4 high voltage wires off the switch. 3 read pack voltage both in f and r BEFORE pressing the pedal. After pressing the pedal it drops down about 11v to 25v. The bottom one closest to the ground (grass/street) reads 0 both before and after pressing pedal. This is the same lead that goes to M-.

Here is a schematic that ought to be wired like yours is. It is for a 48V system, but the wiring should be the same.

Based on your voltage readings, the the "C" (bottom) contact isn't making good contact.

[Chris379]

Ordered a new switch, it's in just need to hook up wires but baby woke up. Fingers crossed its this $100 part and not a $500 controller...